ST UM0575, STEVAL-IHT003V1 User Manual

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Page 1

February 2009 Rev 1 1/20

UM0575

User manual

STEVAL- IHT003V1, e-STARTER demonstration board

based on the ACST6 and X02

Introduction

The e-STARTER demonstration board (Figure 1) presents an innovative solution, patented by STMicroelectronics, to reduce the power losses due to the positive thermal coefficient (PTC) resistors in compressor starter circuits.

This solution features an ACST6 device which is used to turn off the PTC current after the motor startup. It should be noted that the traditional PTC is still used in the electronic starter circuit because it increases safety in case of ACST short-circuit or diode-mode failure (ref. EN60335-1). This solution allows the starter standby losses to be decreased from typically

2.5 W to 380 mW or 40 mW, respectively for 230 V and 100 V applications.

The e-STARTER operation principle along with detailed schematics are given as well as demonstration board performances and the method to adapt the circuit to a dedicated compressor.

It should be noted that this board is not a "plug and play" solution. First, the PTC behavior has to be checked (especially V

PTC1

& V

PTC2

levels as explained in Section 3.1) and then

the R4 resistor value has to be chosen before using the board with a compressor.

Figure 1. STEVAL- IHT003V1, e-STARTER demonstration board

AM01038v1

www.st.com

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Contents UM0575

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Contents

1 Operation principle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.1 Compressor starter application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.2 Standard PTC behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

1.3 e-STARTER operation mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

1.3.2 ON state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2 Board performances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 Maximum current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 Standby power losses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.3 Fast transient voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.4 Surge voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2.5 Reliability and safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 Getting started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.1 Voltage level setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

4 Conclusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Appendix A Component layout and printed circuit board . . . . . . . . . . . . . . . . . 15

Appendix B Bill of material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Page 3

UM0575 List of figures

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List of figures

Figure 1. STEVAL- IHT003V1, e-STARTER demonstration board . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Figure 2. Compressor starter application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Figure 3. PTC operation, no RUN cap. (compressor OFF time > 10' mains: 198 V RMS) . . . . . . . . . 5

Figure 4. PTC operation with RUN cap.(compressor OFF time < 1' mains: 264 V RMS) . . . . . . . . . . 5

Figure 5. e-STARTER schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Figure 6. Voltage spikes at zero current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 7. PTC turnoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Figure 8. e-STARTER maximum current versus conduction time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Figure 9. Spurious e-STARTER triggering with a 2 kV surge (230 V compressor) . . . . . . . . . . . . . . 10

Figure 10. e-STARTER voltage limited to 648 V thanks to the RUN capacitor

(2 kV IEC61000-4-5 surge) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Figure 11. VPTC1 and VPTC2 definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Figure 12. e-STARTER connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Figure 13. e-STARTER topside silk screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Figure 14. e-STARTER SMD components layout (bottom view) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Figure 15. e-STARTER copper side (bottom view, dimensions in cm) . . . . . . . . . . . . . . . . . . . . . . . . 16

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Operation principle UM0575

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1 Operation principle

1.1 Compressor starter application

Single-phase induction motors, used for compressor control, use an auxiliary winding. This

winding permits a higher torque to be applied at startup. The most popular method to control

the start winding is to add a positive temperature coefficient (PTC) resistor in series with this

winding and the thermostat (Figure 2). Then, each time the thermostat is closed, the current

flows through the start winding and begins to heat the PTC. After a few hundreds of

milliseconds, the PTC value rapidly increases from a few W to several tens of kW. This

results in reducing the start winding current to a few tens of mA. This winding can then be

considered as open. The PTC then behaves like a switch in OFF state, but with a high

leakage current, resulting in high power losses (approx. 2.5 W).

Figure 2 gives the typical schematics of this application where a run or a start capacitor can

be connected in parallel (point 1) or in series (point 2) respectively with the PTC.

1.2 Standard PTC behavior

The transition between PTC ON and OFF states brings a voltage increase across this

variable resistor. Figure 3 and Figure 4 show two oscillograms of the same PTC in two

different operating conditions, for a 230 V compressor which can use both a start and run

capacitor. We see that, at the end of the PTC conduction, the voltage across it reaches

approximately 250 V (refer to "VPTC_OFF" indication). This voltage level is similar whatever

the operating conditions are (min or max RMS line voltage, run capacitor or not, etc.). The

PTC could be turned off as soon as this level has been reached. Section 1.3 explains how to

implement an electronic solution to achieve this function.

Figure 2. Compressor starter application

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UM0575 Operation principle

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1.3 e-STARTER operation mode

1.3.1 Schematics

Figure 5 gives the typical schematics of an "e-STARTER" for a 230 V application. The

demonstration board presented here also features some optional pads to add a snubber

(components R6 and C4) as shown in Appendix A and B. The figure also gives the names of

the main electrical parameters which will be detailed in the following sections.

The traditional PTC resistor has to be connected between the "START" and the "PTC"

solder pads (refer also to Section 3.2).

Note: The C3 capacitor is not soldered on the breadboards. It can be added if one wants to

evaluate its impact on board immunity.

Figure 3. PTC operation, no RUN cap.

(compressor OFF time > 10' mains: 198 V RMS)

Figure 4. PTC operation with RUN

cap.(compressor OFF time < 1' mains: 264 V RMS)

PTC

(100V/div)

PTC

(10A/div)

PTC_OFF

PTC

(100V/div)

PTC

(10A/div)

PTC

(100 V/div)

PTC

(10 A/div)

PTC_OFF

AM00899v1

PTC

(100V/div)

PTC_OFF

PTC

(10A/div)

AM00900v1

Page 6

Operation principle UM0575

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1.3.2 ON state

As soon as the mains voltage is applied:

● M1 is OFF because the voltage drop across the PTC is not high enough to reach the

DZ1 clamping level

● T2 is then turned on, thanks to the gate current provided by R2

● T1 is turned on thanks to the gate current provided by T2

Both T1 and the PTC are then ON.

At each zero-current crossing point, the ACST6 turns off. The reapplied voltage across

T1/T2 triggers back T1 which results in some voltage spikes at each zero-current crossing

point (typically around 40 V as shown in Figure 6 for a 230 V compressor).

Applying the click test of norm EN55014, the noise duration could last more than 200 ms

(depending on the type of compressor and PTC). The individual spikes last a few hundreds

of microseconds and are spaced at intervals of 10 ms, so the limits of continuous

disturbance are applicable. Since the spike peaks are less than 100 V, the e-STARTER

solution should fulfill the requirements of EN55014. It should be noted that tests results

greatly depend on the compressor used during the tests.

Figure 5. e-STARTER schematics

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UM0575 Operation principle

7/20

When the PTC conduction time has been sufficient to start the compressor, its voltage

suddenly rises. This voltage rise is sensed by the R3/R4 divisor bridge.

If the level is higher than the DZ1 clamping level, the thyristor, consisting of Q1 and Q2, is

latched. M1 is then turned on.

As M1 is ON, there is no more gate current to trigger T2, so T1 also stays OFF. The PTC is

then turned off.

No more current circulates through the PTC, thus no power is dissipated in it.

Figure 7 shows the typical behavior of this circuit. The C1 capacitor voltage gives an image

of the PTC voltage. When its value reaches the DZ1 clamping level (15 V), the MOS gate is

latched to 15 V. The PTC is then turned off (refer to the IA ACST6 current waveform).

Figure 6. Voltage spikes at zero current

Figure 7. PTC turnoff

IA(5A/div)

VAK(20V/div)

IA(5 A/div)

(20 V/div)

AM00902v1

IA(5A/div)

VC2(10V/div)

VC1(10V/div)

AM00903v1

Page 8

Board performances UM0575

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2 Board performances

2.1 Maximum current

During e-STARTER conduction, the power losses are similar to those of the standard PTC

solution as the same current circulates through this resistor. The only difference is that a

small part of the voltage is also held by T1.

In the case of an ACST6, its forward voltage drop can be considered to be a constant

forward voltage, V

, of at worst 0.8 V and a dynamic resistance, Rd, of at worst 80 m. So

even with a 10 A peak current, the voltage drop is less than 1 V.

This forward voltage drop should be taken into account mainly to evaluate the junction

temperature elevation of the semiconductor switch.

For an ACST6 in the TO220AB package, without any heatsink, this junction temperature

elevation is equal to:

● 30° C after a 5 A RMS current during 3 s (worst case of typical 100 V/60 Hz

compressors)

● 50° C after an 11 A RMS current during 0.5 s (worst case of typical 230 V/50 Hz

compressors)

This ensures that T

remains below its maximum allowed temperature (125° C), even with a 75° C initial temperature. Figure 8 gives the maximum repetitive RMS current that the ACST6-7ST can withstand without any heatsink. This curve is given for 40° C and 75° C ambient temperatures. As with the e-STARTER solution, the heating time of the PTC is not long enough to warm the electronic devices, so the 40° C curve is closer to the real e-STARTER operating conditions.

2.2 Standby power losses

During e-STARTER standby, the losses are caused only by the resistors, which are still connected to the mains voltage. Indeed, the ACST leakage current is in practice very much lower than 20 µA so that the resulting losses can be neglected.

Figure 8. e-STARTER maximum current versus conduction time

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UM0575 Board performances

9/20

The two resistors which are mainly dissipating power at standby are:

● R2 - used to provide T2 with gate current during the e-STARTER on state

● R3 - used to sense the voltage level across the PTC

As R2 is connected just behind the diodes’ bridges, the V

voltage is applied across it, in full-wave mode. R3 senses only half the voltage across the PTC and T1. This voltage is also equal to V

as T1 is OFF, and so no current is circulating through the PTC.

We can neglect the voltage drops of M1 and of C1, which are lower than 0.6 V and 16 V respectively. The power losses, dissipated by the two resistors, are given by the following equations:

Equation 1

An example with R2 = 470 kΩ and R3 = 510 kΩ gives:

● For a 230 V / 50 Hz application using a run capacitor, V

can reach up to 350 V RMS.

The overall power losses then equal 380 mW.

● For a 100 V / 60 Hz application using or not a run capacitor, V

stays around the line

voltage, i.e at worst 115 V RMS. The overall power losses then equal 41 mW.

2.3 Fast transient voltages

Immunity tests, as described by the IEC 61000-4-4 standard, have been performed with the schematics of Figure 5, connected in series with a compressor without a RUN or START capacitor. e-STARTER spurious triggerings have not been detected with spikes up to 2 kV.

This high immunity level has been reached thanks to:

● the high dV/dt capability of the ACST6

● the improved dV/dt capability of the very sensitive SCR X0202M (20 µA < Igt < 50 µA)

thanks to the fact that its gate is short-circuited to the cathode via M1 in OFF state, and also thanks to the R6-C4 snubber circuit

● the R

(R7) resistor which is added on the ACST6 device to derivate the current

provided by R2 when M1 is ON

● the immunity provided by the layout of the printed circuit board (refer to Figure 15)

It should be noted that spurious triggering of the e-STARTER is not a problem as such behavior is not seen by the end user, and as these turn-ons do not lead to any component failure.

2.4 Surge voltages

The ACST6 device is an overvoltage protected device which means that it can be used without any varistor in parallel with its terminals. If a high energy surge is applied to the

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Page 10

Board performances UM0575

10/20

mains, as described in the IEC 61000-4-5 standard, when the e-STARTER is off, two cases can occur:

● A no-run capacitor is connected across the e-STARTER: the surge voltage is then

entirely held by the ACST6. If the energy is high enough, the leakage current of the device can exceed its break-over level, leading to a turn-on of the e-STARTER lasting at worst 10 ms (refer to

Figure 9).

● A run capacitor is used: the surge energy is absorbed by this capacitor. The voltage

level is then limited below 1 kV, which is the typical clamping level of the ACST6. No spurious turn-on occurs in this case (refer to

Figure 10).

It should be noted that in case of a spurious triggering in break-over mode, the ACST6 current is limited by the START winding inductance. The current value is then typically in the range of 2 A. This is far below the level guaranteed with ACST6, where a 47 Ω load can be used in such operation mode (refer to the ACST6 datasheet). With a 2 kV surge, the peak current then equals 40 A in this case.

2.5 Reliability and safety

Reliability tests have been performed with ACST6-7ST samples submitted to a current shape equivalent to an inrush current of 11 A RMS during 0.5 s. No parameter evolution of these samples has been detected after 450,000 cycles, which is representative of the lifetime of a refrigerator. This result demonstrates the excellent capability of these 6 A products even for applications with high inrush currents.

Concerning safety, the EN6033561 standard imposes the consideration of short-circuit or diode-mode failures of all silicon power switches involved in safety features. The failure of an entire e-STARTER cannot lead to safety issues (electrical or mechanical shock, fire). If the e-STARTER power switch dies in short-circuit or diode-mode, the start winding current is still limited by the PTC. The start winding is then protected and the compressor still works. Indeed, the starter function is still ensured by the PTC. The only drawback is that the standby losses increase back to 2.5 W.

Figure 9. Spurious e-STARTER triggering

with a 2 kV surge (230 V compressor)

Figure 10. e-STARTER voltage limited to 648 V

thanks to the RUN capacitor (2 kV IEC61000-4-5 surge)

AM00905v1

+ 648 V

MAINS

+ 648 V

MAINS

AM00906v1

Page 11

UM0575 Board performances

11/20

If a failure occurs on the control side, leading to a short-circuit of both the power switch and the PTC, then the start winding could be damaged as its current would not be limited. The solution is then to use a thin copper track (

Figure 15) between the start winding terminal and

the e-STARTER control circuit. For example, a 130 µm track conducts the 1mA peak current in normal operation but blows if the whole start winding current, at least equal to 5 A RMS, circulates through it. The ACST6 then remains on the entire time the thermostat switch is closed. The behavior is the same as a standard PTC, without the power saving function of the e-STARTER.

Page 12

Getting started UM0575

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3 Getting started

3.1 Voltage level setting

To make the demonstration board operate with a given compressor-PTC couple, the only thing to do is to check the divisor ratio of the R3/R4 resistors bridge.

First, the PTC voltage level, which is representative of a long enough START winding activation, has to be defined. This level is called "V

PTC-OFF

To proceed, we propose to measure the PTC peak voltages in ON and in OFF state for the whole range of operation, that is:

● min and max values of the line voltage

● at least one sample of all different compressors that could be used with the

e-STARTER

● min and max values of the ambient temperature.

The PTC peak voltages in ON and in OFF state are called V

PTC1

and V

PTC2

respectively

(refer to the dashed lines in

Figure 11).

Then, the "V

PTC-OFF

" level has to be chosen higher than the maximum value of V

PTC1

order to ensure that the ACST6 has indeed been turned on at the beginning. The "V

PTC-

OFF

" level also has to be lower than the minimum value of V

PTC2

in order to turn off the

ACST6 at the end of the required PTC conduction time.

In order to ensure a safe margin between these two levels, V

PTC-OFF

should be calculated

using the following equation:

Equation 2

According to Figure 4, the maximum V

PTC1

level is 220 V. According to Figure 3, the

minimum V

PTC2

level (198 V RMS line, no RUN cap, test conditions) equals 320 V (from the

Figure 11. V

PTC1

and V

PTC2

definitions

PTC1

PTC2

PTC

PTC1

PTC2

PTC

AM00907v1

MIN2PTCMAX1PTC

OFF_PTC

Page 13

UM0575 Getting started

13/20

figure). Using Equation 2, we then choose a 250 V level for V

PTC_OFF

to give the end of

START winding conduction information.

To achieve this level detection, R4 has to be chosen according to the value of R3, using the following equation:

Equation 3

where V

DZ1

is the clamping level of the Zener diode and V

BE_Q1

is the forward voltage drop

of the base-emitter junction of the Q1 transistor.

With R3 remaining at 510 kΩ (to reduce the power losses), V

DZ1

and V

BE_Q1

are 15 V and

0.6 V respectively, then R4 equals:

Equation 4

3.2 Connections

Before beginning any test, please take note of the following warnings:

1. The board has to be used by electrically-skilled technicians or engineers because the

board has to be plugged into the mains and because no insulation is used between the mains voltage and the accessible conductive parts.

2. There is no insulation varnish on solders. Care should be taken when performing

measurements (for example, voltage probes have to be connected only when the line and the power supply voltages are removed).

The e-STARTER has to be connected to a PTC and a compressor as shown in

Figure 12,

according to the instructions given on the topside silk screen. The RUN capacitor (CRUN) is optional and has to be used according to the compressor type. A start capacitor could also be placed in series between the PTC and the e-STARTER.

1Q_BE1DZOFF_PTC

1DZ

VVV

3R4R

−−

⋅=

Ω≅⋅=

−−

⋅⋅= k30106.32

6.015250

105104R

Figure 12. e-STARTER connections

Vac

Thermostat

Klixon

PTC

Compressor

e-STARTER

RUN

PTC

RUN

Vac

Thermostat

Klixon

PTC

Compressor

RUN

PTC

START

AM00908v1

Page 14

Conclusion UM0575

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4 Conclusion

This demonstration board promotes a full ST silicon kit for thermostat applications and allows users to:

● check the immunity of our solution

● easily check the efficiency gains

● adapt the hardware for dedicated compressors & PTCs.

The e-STARTER allows the designers of cold appliances to upgrade the efficiency class of refrigerators or freezers with a very low cost solution. This solution allows the starter standby losses to be decreased from typically 2.5 W to 380 mW or 40 mW, respectively for 230 V and 100 V applications. The high reliability and immunity of this circuit are ideally suited to the severe requirements of a refrigerator or freezer application.

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UM0575 Component layout and printed circuit board

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Appendix A Component layout and printed circuit board

Figure 13 and Figure 14 give the layout of the components for the top and the bottom layers,

respectively.

Figure 15 gives the copper side of the e-STARTER demonstration board.

Figure 13. e-STARTER topside silk screen

AM00909v1

Page 16

Component layout and printed circuit board UM0575

16/20

Figure 14. e-STARTER SMD components layout (bottom view)

Figure 15. e-STARTER copper side (bottom view, dimensions in cm)

AM00910v1

AM00911v1

Page 17

UM0575 Bill of material

17/20

Appendix B Bill of material

The following table gives the bill of material of the e-STARTER board for a 230 V application. The values are given for indication as some values can be changed to adapt the voltage level detection (R3, R4, DZ1) or to increase the board immunity (R6, C4, R7, C2, C3, R8, C1).

Table 1. e-STARTER bill of material

Index Qty Reference Name Package Manufacturer

Manufacturer’s ordering

code / orderable part

number

1 1 TRIAC T1 TO-220 STMicroelectronics ACST6-7ST

2 1 SCR T2 SOT-223 STMicroelectronics X0202NN 5BA4

3 1 PNP transistor Q1 SOT-23 Philips PMBT2907A

4 1 NPN transistor Q2 SOT-23 Philips PMBT2222A

N-Channel

transistor

M1 SOT-23 Fairchild MMBF170

Resistor 620 kΩ

1/4 W 1%

TH,

Axial,0207

Resistor 470 kΩ

1/4 W 1%

TH,

Axial,0207

Resistor 510 kΩ

1/4 W 1%

TH,

Axial,0207

Resistor 30 kΩ

1/4 W 1%

TH,Axial,020,

pitch 2,5

10 1

Resistor 10 kΩ

1/4 W 1%

R5 TH,Axial,0207

11 1 Resistor 0 1/4 W R6 TH,Axial,0207

12 1

Resistor 220

1/4 W 1%

R7 SMD 1206

13 1

Resistor 1 M

1/4W 1%

R8 TH,Axial,0207

14 1

Ceramic capacitor

10 nF/50 V 20%

C1 SMD 1206

15 1

Ceramic capacitor

10 nF/50 V 20%

C2 SMD 1206

16 1

No capacitor

connected

C3 SMD 1206

17 1

Capacitor 22 nF /

250 VAC

C4 TH, pitch 11

18 1

Single phase

bridge rectifier

DF06 DIL DB-1 WTE / GOOD-ARK DF06

Page 18

Bill of material UM0575

18/20

19 1

General purpose

rectifier, 1N4007

(1000 V,1 A)

D1 DO214 SMA

20 1

Small signal

diode, 1N4148

(75 V,0.15 A)

D2 DO-35

21 1 Zener diode DZ1 DO-35 Fairchild / Vishay BZX55C 15

Table 1. e-STARTER bill of material (continued)

Index Qty Reference Name Package Manufacturer

Manufacturer’s ordering

code / orderable part

number

Page 19

UM0575 Revision history

19/20

Revision history

Table 2. Document revision history

Date Revision Changes

13-Feb-2008 1 Initial release

Page 20

UM0575

20/20

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