STMicroelectronics STEVAL-CTM004V1, STEVAL-CTM006V1, STEVAL-CTM009V1, STEVAL-CTM005V1, STEVAL-CTM008V1 User Manual

Introduction

The STEV

AL-CTM009V1 evaluation kit for motor control is designed to demonstrate the capabilities of ST Power MOSFETs
based on STripFET™ F7 technology. The 100V STripFET™ F7 devices (STH31*N10F7) are ideal for low voltage (up to 48 V),
high current applications such as forklifts, golf carts and power tool.

The STEVAL-CTM004V1 power board features an insulated metal substrate (IMS), NTCs for thermal protection and decoupling
gate resistors for each power MOSFET. The board mounts ST devices in the H²PAK-6 package.

The driver stage is an STEVAL-CTM006V1 board with L6491 high current capability gate drivers to drive the power MOSFETs
and integrated comparator for protections. The driver board includes the ST motor control connector, so you can interface the
STEVAL-CTM009V1 with any ST MCU control board suitable for motor control (not included in the kit).

The system also has an STEVAL-CTM005V1 bus link capacitor board and an STEVAL-CTM008V1 current sensing board.

Figure 1. STEVAL-CTM009V1 evaluation kit

5 kW low voltage high current inverter for industrial motor control applications

UM2458

User manual

UM2458 - Rev 1 - October 2018
For further information contact your local STMicroelectronics sales of

fice.

www.st.com

1 Evaluation kit features

1.1 Electrical and functional characteristics

The kit features the following main characteristics:

•

Power board with insulated metal substrate (IMS) hosting 36 STH310N10F7 or STH315N10F7 power
MOSFETS in the H²PAK-6 (6x switch) package, designed also for automotive applications.

• High and low-side, high current capability (L6491) gate driver with integrated comparator for fast protection
and smart shutdown functions.

• Maximum power 5 kW at 48 V.

• Isolated current sensing, bus voltage and temperature monitoring.

1.2 Target applications

The STEVAL-CTM009V1 kit is designed for applications involving motor drives for electric traction, such as:

•

forklifts

• golf carts

• E-rickshaw

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2 Safety and operating instructions

2.1 General terms

All operations involving transportation, installation and use, as well as maintenance, has to be carried out by
skilled technical personnel (national accident prevention rules must be observed). For the purpose of these basic
safety instructions, "skilled technical personnel" are considered as suitably qualified people who are familiar with
the installation, use, and maintenance of power electronic systems.

2.2 Intended use of evaluation kit

This evaluation kit is designed for demonstration purposes only and shall not be used for any commercial
purpose. The technical data, as well as information concerning power supply conditions, must be taken from the
relevant documentation and strictly observed.

2.3 Evaluation kit setup

• The evaluation kit must be set up in accordance with the specifications and the targeted application.

•

The board contains electro-statically sensitive components that are prone to damage through improper use.
Electrical components must not be mechanically damaged or destroyed.

• Avoid any contact with other electronic components.

• During the motor driving, converters must be protected against excessive strain. Do not bend or alter the
isolating distances any components during transportation or handling.

2.4 Electronic connections

Applicable national accident prevention rules must be followed when working on the main power supply with a
motor drive. The electrical installation must be completed in accordance with the appropriate requirements. A
system architecture which supplies power to the evaluation board must be equipped with additional control and
protective devices in accordance with the applicable safety requirements (e.g., compliance with technical
equipment and accident prevention rules).

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3 Evaluation kit overview

The STEVAL-CTM009V1 evaluation kit is designed to let you evaluate STH31*N10F7 power MOSFETs, which
are driven by high and low-side, L6491 high current capability gate drivers. The system includes a bulk capacitor
board and a current sensing board.

The STEV

AL-CTM009V1 can be interfaced with any ST MCU evaluation board with embedded ST motor control

and ST FOC firmware library support.

This kit has been tested with the STEVAL-CTM001V1C (not included in this kit) control board of the STEVAL­HKI001V1 kit), which features an STM32F303RB 32-bit microcontroller.

Figure 2. STEVAL-CTM009V1 block diagram

DRIVING STAGEPOWER STAGE

Not used

Motor Control

ICS

Ph_U driving

circuitry

Ph_V driving

circuitry

Ph_W driving

circuitry

Vin

L6491
driver

3V3 DC/DC

5V DC/DC

12V DC/DC

DRV->PW DRV->PW DRV->PW

L6491
driver

L6491
driver

ENC/HALL

PW->DRV

PW->DRV

PW>DRV

12x

STH315N10F7

in H

2

P

AK-6

-

Phase_U Phase_V Phase_W

Shunt

resistor

Shunt

resistor

Shunt

resistor

12x

STH315N10F7

in H

2

P

AK-6

12x

STH315N10F7

in H

2

P

AK-6

connector on top

connector on bottom

NTC

LEGEND

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4 STEVAL-CTM004V1 power board

The STEVAL-CTM004V1 power board of the evaluation kit has 36 STH31*N10F7 N-channel Power MOSFETS in
the H²P

AK-6 package. A gate resistor is placed near each power MOSFET to eliminate parasitic oscillation. A
pull-down resistor between the gate and the source of each transistor helps to avoid capacitive coupling driving
the transistor and unwanted switch-on when gate is floating. A snubber RC circuit on each switch limits the rate of
voltage change during switching transitions to reduce electromagnetic interference (EMI) and losses.

two decoupling capacitors close to the switching power MOSFETs reduce ringing on the VDS and voltage stress
on the devices. The capacitors reduce voltage overshoot caused by abrupt current change in the parasitic
inductors in the circuit.

To monitor the temperature of the power board and provide over-temperature protection, three NTCs are placed
on the power board near the drain of one power MOSFET for each inverter leg.

The power section also has connectors for the driver board, with CON5 (phase_U), CON6 (phase_V) and CON7
(phase_W) for gate driving and NTC sensing, and J3 for bus voltage. The board also hosts six towers near the
bulk capacitor board connection and three towers near the motor connection.

Figure 3. Main blocks of the STEVAL-CTM004V1 power board

4.1 STH315N10F7 N-channel Power MOSFET characteristics

The N-channel Power MOSFETs use STripFET™ F7 technology with an enhanced trench gate structure for very
low on-state resistance and reduces internal capacitance and gate charge for faster and more ef

ficient switching.

The STH315N10F7 N-channel Power MOSFET has the following features:

• Designed for automotive applications and AEC-Q101 qualified

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• Among the lowest R

DS(on)

on the market

•

Excellent figure of merit (FoM)

• Low C

rss/Ciss

ratio for EMI immunity

• High avalanche ruggedness

Figure 4. Package and internal schematic diagram

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5 Driver board and control board overview

Figure 5. STEV

AL-CTM006V1 driver board functional blocks

1. connections to power board

2. motor control connector

3. ENC/HALL connector

4. ICS connector

5. L6491 drivers
6 3V3 DC/DC regulation

7. 5V DC/DC regulation

8. 12V DC/DC regulation

1

1 1

1

5

5

5

4

3

7

8

6

2

5.1 STEVAL-CTM006V1 driver board

5.1.1 Power supply section

The power supply section provides all the voltages necessary for the circuitry. The required input voltage is 8 to
36 V input, which is supplied through connector JP1.

The input voltage is then converted to the following voltage levels:

•

+12V for gate driver section (via an A7986 3 A step-down switching regulator)

• +5V and +3.3V for the control board (via an A6902 1 A switch step-down regulator)

5.1.2 Bus voltage monitoring

Bus voltage monitoring is implemented across an input voltage range of 5 to 75 V.

The following table shows the measured input voltage and the corresponding voltage level sent to the ADC input
of the STM32 microcontroller unit.

T

able 1. Input voltage bus and input signal to STM32 ADC channel

Input Voltage ADC input

48V 2.0V

75V (max value) 3.1V

5.1.3 Temperature monitor

Three NTCs are placed on the power section to provide temperature information, although only one NTC may be
chosen at a time. Close one of the three jumpers S1, S2 or S3 to read the temperature near the U, V or W phase,
respectively

. The microcontroller monitors processed signals to determine the temperature of the driver board and

manage any overload or over-temperature conditions.

To protect the hardware from excess temperature, a safe threshold is set in the STM32 FOC SDK software library.

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Table 2. NTC electrical characteristics

Symbol Parameter Test Condition Min Typ Max Unit

R

-40

Resistance T = -40°C - 105.7 - kΩ

R

25

Resistance T = 25°C - 4.7 - kΩ

R

100

Resistance T = 100°C - 0.426 - kΩ

B B- constant T = 25°C to 50°C - 3500 - -

T Operating temp range -40 125 °C

5.1.4 L6491 gate driver characteristics

The L6491 gate driver has the following main features:

•

dV/dt immunity ± 50 V/ns in full temperature range

• Driver current capability: 4 A source/sink

• Switching times 15 ns rise/fall with 1 nF load

• 3.3 V, 5 V TTL/CMOS inputs with hysteresis

• Integrated bootstrap diode

• Comparator for fault protections

• Smart shutdown function

• Adjustable deadtime

• Interlocking function

• Compact and simplified layout

• Bill of material reduction

• Effective fault protection

• Flexible, easy and fast design

For detailed information on the product, see the device datasheet.

Figure 6. L6491 gate driver pin-out

Table 3. Pin functions of L6491 gate driver

Pin number Pin name Type Function

1 LIN I Low-side driver logic input (active low)

2

SD / OD I/O

Shutdown logic input (active low)/open-drain

comparator output

3 HIN I High-side driver logic input (active high)

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Pin number Pin name Type Function

4 VCC P Lower section supply voltage

5 DT I Deadtime setting

6 SGND P Signal ground

7 PGND P Power ground

8 LVG O Low-side driver output

9 CP- I Comparator negative input

10 CP+ I Comparator positive input

11 NC Not connected

12 OUT P High-side (floating) common voltage

13 HVG O High-side driver output

14 BOOT P Bootstrapped supply voltage

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6 STEVAL-CTM005V1 bus link capacitor board

In EV inverter systems, bus link capacitors reduce ripple current and suppress voltage spikes caused by leakage
inductance and switching operations. These capacitors provide a low impedance path for the ripple currents
caused by output inductance load, the bus voltage and PWM frequency

.

The bus link capacitors must sustain a ripple current given by the following formula:

ΔI

0.5t

=

0.25 ×

V

b

us

f × L

Where:

•

ΔI

0.5t

is the maximum ripple current when duty cycle is 50%

• V

bus

is the bus voltage

• f is the switching frequency

• L is the load inductance.

For a very low inductance motor (worst case scenario), ΔI

0.5t

is about 48 A

RMS

(V

bus

= 52 V, f = 8 kHz and

L = 12 μH). If we add 10% to ΔI

0.5t

and choose electrolytic capacitors with a ripple current of 2.4 A, 22 electrolytic

capacitors are required. The resulting capacitance is about 6 mF, leading to a negligible ripple voltage on the bus.

Figure 7. STEVAL-CTM005V1 bus link capacitor board

6.1 STEVAL-CTM008V1 current sensing board

The STEVAL-CTM008V1 current sensing board is a general purpose board for motor control that can read up to
three phase motor currents and DC bus currents if four ICS are on-board. The board included in the kit hosts two
ICS to read two phase currents.

This sensing feature determines motor currents for digital control based on FOC algorithms. The sensors provide
high accuracy

, with 4 mV/A over a temperature range of -40 °C to +105 °C and a nominal current of 200 A

RMS

.

The internal reference voltage of the ICSs (according to their VCC) is generally used, but the reference voltage
can be overdriven by providing an external reference voltage through the J1 connector. A female to female flat

cable is used to connect CON2 on the driver board with J1 on the current sensing board.

The signals from the sensors center around 1.65 V (average value at zero current).

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Figure 8. STEV

AL-CTM008V1 current sensing board

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7 How to set up the system

Follow the steps below to set up the evaluation kit.

Step 1. Mount the STEV

AL-CTM004V1 power board heatsink.

Use standard thermal interface material or a graphite sheet for high thermal conductivity

Step 2. Connect the STEVAL-CTM004V1 power board with the STEVAL-CTM006V1 driver board.

– use connectors CON5, CON6, CON7 and J3 on the STEVAL-CTM004V1 power board

– use connectors CON1, CON3, CON4 and J2 on the STEVAL-CTM006V1 driver board

Step 3. Connect the control board:

– If you use the STEVAL-CTM001V1C control board (not included in the kit):

◦ use connectors J1 and J4 on the STEVAL-CTM006V1 driver board

◦ use connectors CON3 and CON1 on the STEVAL-CTM001V1C control board.

– If you use a control board that is not the STEVAL-CTM001V1C:

◦ Use connector J1 on the driver board.

Step 4. Mount the STEVAL-CTM005V1 bus link capacitor board on the STEVAL-CTM004V1 power board

Step 5. Set up the STEVAL-CTM001V1C control board (optional, if present).

– close jumper SW5 in the default position (indicated near the switch)

– connect ST-LINK to the CON14 connector

– connect the USB to serial converter to the P2 with a serial cable DB9 female to female

Step 6. Set up the STEVAL-CTM006V1 driver board.

– close jumper S1, S2 or S3 to read one of the three NTCs on the power stage

– connect a 12 V DC power supply to the JP1 connector and turn on the power supply

Step 7. Connect the flat cable between CON2 on the STEVAL-CTM006V1 driver board and J1 on the STEVAL-

CTM008V1 current sensing board.

Step 8. Connect a 48 VDC power supply to the STEVAL-CTM006V1 driver board.

Step 9. Connect the phase motor cables to the STEVAL-CTM004V1 power board.

7.1 Connectors

In addition to the connector used for the supply voltage, the driving board has connectors to plug it to the power
board and the control board, and to receive external signals.

•

Connector for supply voltage: provided at JP1 (8 to 36 V).

• Connectors to the power board:

– CON1, CON3 and CON4: for power MOSFET driving and NTC sensing.

– J2: connector for DC bus voltage sensing (fpr undervoltage and overvoltage protection).

• Connectors to the control board

– J1: motor control connector, including signals like fault management, bus voltage monitoring, power

board temperature sensing and current sensing.

– J4: connector used for mechanical robustness when a control board (e.g., STEVAL-CTM001V1C, not

included in kit) is plugged but not electrically connected.

• Connectors for external signals

– CON8 (ENC/HALL connector): to receive external signals from Encoder/Hall sensors and provides

+3V3 or +5V supply voltages.

– CON2 (CURRENT SENSING connector): to receive current signals from the external current sensor

board and provide a +5V supply voltage.

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