24 July 2008 Data Sheet No. PD60359 IRMD26310DJ 3 PHASE GATE DRIVER IC REFERENCE DESIGN KIT IRS26310DJ GATE DRIVER IC FEATURES • • • • • • • • • • • • • • • • • Drives up to six IGBT/MOSFET power devices Gate drive supplies up to 20 V per channel Integrated bootstrap functionality DC bus sensing with Over Voltage protection Over-current protection Over-temperature shutdown input Advanced input filter Integrated deadtime protection Shoot-through (cross-conduction) protection Under voltage lockout for VCC & VBS Enable/disable input and fault reporting Adjustable fault clear timing Separate logic and power grounds 3.3 V input logic compatible Tolerant to negative transient voltage Designed for use with bootstrap power supplies Matched propagation delays for all channels Product Summary AC input Voltage (typ.) 220 V rms Continuous motor current 3 A rms dV/dt 5 kV/µs Bus over voltage protection (typ.) 386 V Continuous output power 400 W REFERENCE DESIGN FEATURES • • • • • Complete 3-phase ac motor drive system to showcase IRS26310DJ gate driver IC operation No extra hardware needed for PWM signal generation; Option to incorporate external PWM signals to drive IRS26310DJ if desired GUI software for running Induction Motor in open loop Volts-per-Hertz mode of operation Discrete IGBT power stage for maximum flexibility o o IGBT’s rated for 10A @100 C o Short circuit rating 10 µs o TO220 Full-pak package Conveniently located Test points for IRS26310DJ signal monitoring Overview The IRMD26310DJ is a reference design kit for the IRS26310DJ three phase gate driver IC with integrated bootstrap functionality and DC bus overvoltage protection. The design kit includes a complete drive system board with an input rectifier, control power supplies, digital motor control IC and power inverter. Safety features include protections against motor line-to-line, line-to-DC Bus(-) short situations & DC bus overvoltage conditions. The power stage features the IRS26310DJ gate driver and six discrete IGBT power switches allowing for easy customization. The included PC based GUI software allows the user to drive an Induction Motor in open-loop Volts-per-Hertz mode of operation using the on-board digital control IC. The motor speed and system parameters such as PWM frequency and deadtime can be modified using the GUI. Alternately, the IRS26310DJ gate drive input PWM signals can be supplied externally by patching in signals through an on-board connector. Rev 1.3 © 2008 International Rectifier IRMD26310DJ Table of Contents Safety Precautions…………………………………………………………………………………………………….4 IRMD26310DJ Hardware Description………………………………………………………………………............6 Top Level Description………………………………………………………………………………………………6 IRS26310DJ Gate Driver IC……………………………………………………………...………………………..7 Bootstrap Supply……………………………………………………………………………………………………8 Gate Drive Resistors……………………………………………………………………………………………….8 IRMD26310DJ Protection Features……………………………………………………………………………...9 IRMD26310DJ Fault Reporting…………………………………………………………………………………...9 Automatic Reset after ITRIP Fault………………………………………………………………………………..9 IRMD26310 Enable Function…………………………………………………………………………………….10 PWM input to IRS26310DJ & Connection of an external system controller………………………………..10 Test Points for Investigation……………………………………………………………………………………...11 IRMD26310DJ Operating Instructions……………………………………………………………………………..12 Software Installation……………………………………………………………………………………………….12 Test Bench Connection…………………………………………………………………………………………...12 Powering the Board………………………………………………………………………………………………..13 Running the Software GUI………………………………………………………………………………………..14 Software GUI Fault Handling Instructions……………………………………………………………………….17 How to Trigger IRS26310DJ DC Bus Overvoltage Protection………………………………………………..18 IRMD26310DJ Software GUI Reference Guide…………………………………………………...……………...19 Motor Parameters………………………………………………………………………………………………….19 Inverter Parameters………………………………………………………………………………………………..19 System Status………………………………………………………………………………………………………19 Control………………………………………………………………………………………………………………19 Monitors……………………………………………………………………………………………………………..20 Speed Control………………………………………………………………………………………………………20 IRMD26310DJ Circuit Schematics………………………………………………………………………...………..21 IRMD26310DJ Bill of Materials..…………………………………………………………………...………………..25 IRMD26310DJ Specifications…………………………………………………………………………………….....28 www.irf.com © 2008 International Rectifier 2 IRMD26310DJ List of Figures Figure1: IRMD26310 system block diagram…………………………………………………………………………6 Figure 2: Picture of IRMD26310 reference design…………………………………………………………………..7 Figure 3: IRS26310 application diagram……………………………………………………………………………...7 Figure 4: Bootstrap circuit……………………………………………………………………………………………...8 Figure 5: Gate circuit……………………………………………………………………………………………………8 Figure 6: Protection circuits, fault reporting & automatic reset after ITRIP fault………………………………..10 Figure 7: 20 Pin connector, P1……………………………………………………………………………………….10 Figure 8: Test bench connection……………………………………………………………………………………..12 Figure 9: Board connections………………………………………………………………………………………….13 Figure 10: 8 pin connector, J1………………………………………………………………………………………..13 Figure 11: Location of diagnostic LEDs in IRMD26310DJ………………………………………………………...14 Figure 12: Software GUI before establishing communication between IRMD26310DJ and PC………………14 Figure 13: COM port selection………………………………………………………………………………………..15 Figure 14: Software GUI after establishing communication between IRMD26310DJ and PC………………...15 Figure 15: Software GUI after successful configuration of IRMD26310DJ……………………………………...16 Figure 16: Software GUI while running the motor using IRMD26310DJ…………………………………………17 Figure 17: Software GUI during 2 different fault situations………………………………………………………..17 Figure 18: IRS26310DJ DC bus overvoltage protection…………………………………………………………..18 Figure 19: Zero-vector insertion during IRS26310 DC bus overvoltage protection………………………........18 Figure 20: IRMD26310DJ power stage circuit schematic…………………………………………..……………..21 Figure 21: IRMD26310DJ Digital Control & Communications Circuit Schematic………………….…………...22 Figure 22: IRMD26310DJ RS-232 Drivers & Receivers Circuit Schematic……………………..……………....23 Figure 23: IRMD26310DJ DC-DC Converter Low Voltage Power Supply Circuit Schematic..………………..24 List of Tables Table 1: Gate drive circuit components………………………………………………………………………………8 Table 2: List of test points…………………………………………………………………………………………….11 Table 3: List of faults issued by GUI…………………………………………………………………………………20 Table 4: IRMD26310 electrical specifications………………………………………………………………………28 www.irf.com © 2008 International Rectifier 3 IRMD26310DJ Safety Precautions In addition to the precautions listed throughout this manual, please read and understand the following statements regarding hazards associated with development system. ! ! ! ! ATTENTION: The ground potential of the IRMD26310DJ system is biased to a negative DC bus voltage potential. When measuring voltage waveform by oscilloscope, the scope ground needs to be isolated. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: The IRMD26310DJ system contains dc bus capacitors, which take time to discharge after removal of main supply. Before working on drive system, wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: Only personnel familiar with the drive and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: The surface temperatures of the drive may become hot, which may cause injury. www.irf.com © 2008 International Rectifier 4 IRMD26310DJ ! ! ! ATTENTION: The IRMD26310DJ system contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference applicable ESD protection handbook and guideline. ATTENTION: An incorrectly applied or installed drive can result in component damage or reduction in product life. Wiring or application errors such as undersizing the motor, supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result in system malfunction. ATTENTION: Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Wait three minutes after removing power to discharge the bus voltage. Do not attempt to service the drive until bus voltage has discharged to zero. Failure to do so may result in bodily injury or death. ATTENTION: Do not connect power factor correction capacitors to drive output terminals U, V, and W. Failure to do so may result in equipment damage or bodily injury. ! Debris When Unpacking IRMCS3041 system is shipped with packing materials that need to be removed prior to installation. ATTENTION: Failure to remove all debris and packing materials which are unnecessary for system installation may result in overheating or abnormal operating condition. ! www.irf.com © 2008 International Rectifier 5 IRMD26310DJ IRMD26310DJ - Hardware Description The IRMD26310DJ reference design kit supports the evaluation of the IRS26310DJ which is a high voltage power MOSFET and IGBT driver with integrated DC Bus overvoltage protection. The reference design is a full-function unit operating out of 220VAC input. An onboard digital controller IC enables driving an Induction Motor in openloop Volts-per-Hertz mode. The included GUI software allows modification of system parameters in order to drive an induction motor in open-loop Volts-per-Hertz mode and study the IRS26310DJ high voltage gate driver IC by changing parameters such as PWM frequency and deadtime. In addition to DC Bus overvoltage protection offered by IRS26310DJ, the reference design is equipped with protection against motor line-to-line and line-to-DC Bus(-) short by way of IRS26310DJ ITRIP function and also a GUI software controlled motor current limit. The board includes multiple test points to facilitate monitoring IRS26310DJ input and output signal waveforms and examining its various features. Top Level Description The IRMD26310DJ reference design is composed of the following key blocks: • The Input Stage includes an EMI filter, 8A bridge rectifier and dc bus capacitor rated for 400W continuous operation. It is noted that IRMD26310DJ does not feature a current limiting fuse. o • The Power Inverter uses 6 x IRGIB10K60D1 IGBT power switches mounted on a 1.9 C/W heatsink. The IGBTs can be replaced with user preferred power devices but user may need to replace components such as bridge rectifier & dc bus current shunt to match the device ratings. • The IGBTs in the power inverter stage are driven by the IRS26310DJ Gate Driver and associated circuitry involving bootstrap capacitors, gate drive timing resistors, and fault diagnostic elements. • The Control Circuitry for driving the motor is based on the IRMCF341 digital control IC. The IRMCF341 control IC has been configured to run an induction motor in the open-loop Volts-per-Hertz mode. The control IC generates the PWM signals for IRS26310DJ gate driver. The user also has the option to drive the IRS26310DJ externally by disconnecting the jumpers on connector P1 and bridging in external connections. The digital IC communicates with a PC over an isolated serial link and the included GUI software allows the user to set the motor speed and modify common inverter parameters such as switching frequency and deadtime. • An on-board DC-DC Converter low voltage power supply derives the 15V, 3.3V & 1.8V rails from the main dc bus. For more information regarding the other blocks of the reference design, please refer to the detailed schematics. Figure 1: IRMD26310DJ System Block Diagram www.irf.com © 2008 International Rectifier 6 IRMD26310DJ DC-DC Converter Control Circuitry PC Connector Power Inverter Gate Driver Circuitry Power Connector Input Stage Connector for external PWM drive Figure 2: Picture of IRMD26310DJ Reference Design IRS26310DJ Gate Driver IC The IRS26310DJ IC integrates three independent half bridge drivers with shoot through protection and internal dead-time insertion. Proprietary HVIC technology enables ruggedized monolithic construction with logic inputs compatible with CMOS or LSTTL levels as low as 3.3 V. The output drivers feature a high pulse current buffer stage designed for minimum driver cross-conduction. Propagation delays are matched to simplify use in high frequency applications. The floating channel can be used to drive N-channel power MOSFETs or IGBTs in the high side configuration, which operates up to 600V. The IC is based on “Active High” input logic i.e. a logic HIGH input turns ON the corresponding output and vice versa. In addition to VSS pin, the IC features a COM pin to provide a dedicated, low impedance return path for the low side gate driver which also serves to shunt the highfrequency gate drive currents away from the current sense resistor thus preventing false trips. The IC provides DC bus capacitor protection by activating zero-vector motor braking whenever an overvoltage condition is sensed. This feature should only be used with motors that can withstand short-term short circuit of the motor windings. Other protection features offered by the IC include UVLO for VCC & VBS supplies and motor current trip along with integrated fault diagnostics are also offered in IRS26310DJ. An open-drain FAULT signal is provided to indicate that an over-current or a VCC under-voltage shutdown has occurred. An enable function integrated into the FAULT/ pin allowing the user to terminate all six outputs simultaneously. Figure 3: IRS26310DJ Application Diagram www.irf.com © 2008 International Rectifier 7 IRMD26310DJ Bootstrap Supply The floating high side driver supplies are generated by a bootstrap circuit as shown in Figure 4. The IC turns on the internal ‘bootFET’ when the low side transistor is on to charge up the bootstrap capacitor (Cboot). The ‘bootFET’ eliminates the requirement for an external boot diode Dboot as is the case for previous generation gate drivers. An application note AN-1123 (http://www.irf.com/technical-info/appnotes/an-1123.pdf) describes the selection of the bootstrap capacitor and considerations when using the internal bootFET. In some cases, an external bootstrap circuit may be preferable. The IRMD26310DJ board also provides option for external bootstrap supply. This can be invoked by populating the bootstrap resistor, Rboot (R17) and bootstrap diodes (D6, D7 & D8). The bootstrap capacitors must be fully charged to avoid missing high side pulses due to under voltage lockout on the floating high side supply. The digital controller on the board pre-charges the capacitors by turning on the low side transistors for a short period before starting to run the motor. The charging current and time depends on the resistance of the internal bootFET or the external boot resistance. Typically, the pre-charge sequence charges the capacitors one at a time to avoid spurious over current trips since the charging current flows through the current sensing shunt. Figure 4: Bootstrap circuit Gate drive resistors The IRMD26310DJ board has gate resistor networks to allow fine tuning of the power switch turn on and turn off times. Figure shows the gate circuit schematic while Table 1 list the resistors used in the network for each power device. Figure 5: Gate circuit U V High side gate (HO turn-on/off) R61/R99/D9 R62/R101/D10 Low side gate (LO turn-on/off) R64/R119/D12 R65/R120/D13 Table 1: Gate drive circuit components www.irf.com W R63/R118/D11 R66/R121/D14 © 2008 International Rectifier 8 IRMD26310DJ IRMD26310DJ Protection Features Motor Overcurrent Protection Motor over-current protection is implemented using a dc link shunt resistor (R60) placed between power ground (COM pin) and logic ground (VSS pin) as shown in Figure 6. The ITRIP signal from the shunt has an input RC filter (R38, C37) to reject power inverter noise. The IRS26310D has a comparator that generates a shutdown signal when the ITRIP pin voltage exceeds the ITRIP threshold (VIT,TH+). An internal noise filter rejects pulses shorter than 400ns to avoid spurious trips due to diode reverse recovery current. The shutdown signal turns off all six outputs and pulls the FAULT / EN pin low. When the over-current condition is cleared, the fault remains latched until reset by the voltage on the RCIN. Under-voltage protection circuits The IC monitors the supply voltage on the VCC pin. It turns off all six outputs and pulls the FAULT / EN pin low when VCC falls below a minimum threshold (VCCUV-). This fault is not latched but is cleared once VCC goes above the positive going threshold (VCCUV+). The IC also features UVLO protection for all 3 VBS floating supplies; However, a VBS UVLO condition does not trigger fault reporting i.e. FAULT / EN pin is not pulled low. Under a VBS UVLO condition, only the corresponding gate driver output is terminated until the VBS UVLO condition is cleared. DC Bus over-voltage protection circuits The IRS26310D monitors the dc bus to prevent it charging to an unsafe voltage level during regenerative braking. The divider network R35, R36 and R37 drops the DC bus to a low voltage level and communicates to IRS26310D. A comparator and noise filter detects a bus over-voltage condition when the voltage on the DCBusSense pin goes above a maximum threshold (VDCBUSOV+). The default resistor divider configuration in IRMD26310DJ will trigger IRS26310DJ DC bus overvoltage protection feature at approximately 386V. When an over-voltage condition is sensed, it forces IRS26310DJ into zero vector mode, which turns on all low side transistors and turns off all high side transistors irrespective of the PWM input commands from digital control IC. IRS26310DJ then returns to normal operating mode when the voltage on the DCBusSense pin drops below a minimum threshold (VDCBUSOV). The dc bus over-voltage state is not reported on the FAULT / EN pin. For more information regarding how to trigger the DC bus overvoltage protection feature, please refer to “Operating Instructions” section. IRMD26310DJ Fault Reporting The FAULT / EN pin of the IC is used to communicate a fault situation to the digital control IC (DCIC). The FAULT / EN pin, which is normally pulled up to 3.3V using pull up resistor, is connected to the GATEKILL pin on the IRMCF341. When the IC detects a fault situation (either due to VCC UVLO or ITRIP) all gate driver outputs are shut-down and the FAULT / EN pin is pulled low and this triggers the GATEKILL function of IRMCF341 causing all PWM outputs of IRMCF341 to be shutdown. Fault reporting is performed only for the following: - Motor overcurrent (ITRIP) - VCC supply UVLO It is again noted that VBS UVLO & dc bus overvoltage situations do not trigger a fault situation. Automatic Reset after ITRIP Fault Automatic fault reset provided by the HVIC is based on the time constant (RCreset) of the passive network on the RCIN pin. An RC network (R39, C38) between the RCIN pin and VCC supply allows an automatic reset of the ITRIP fault. The capacitor on the RCIN pin is held low as long as the ITRIP comparator input exceeds the ITRIP voltage threshold. When the ITRIP fault condition clears, the capacitor is allowed to charge up. The ITRIP fault is reset when the capacitor voltage exceeds a minimum threshold (VRCIN,TH+). The RCIN auto-reset time can be calculated from the following equation: Vcc t = R39 ⋅ C38 ln Vcc − VRCinTH + The reference design auto reset time is approximately 1.6ms for Vcc=15V, VRCinTH+=8V and R39=2MOhm, C38=1nF. The on resistance of the reset FET on the RCIN pin cannot be neglected so a relatively small capacitor should be used so that it becomes fully discharged before the fault is released. www.irf.com © 2008 International Rectifier 9 IRMD26310DJ IRMD26310 Enable Function The IC features an Enable function integrated into the FAULT / EN pin to provide enable/disable functionality. The IC functionality is enabled when EN pin is biased high. In the IRMD26310DJ reference design, the FAULT / EN pin is pulled up to 3.3V DC bus using resistor R28 potential to always enable operation. Figure 6: Protection circuits, Fault Reporting & Automatic Reset after ITRIP fault PWM input to IRS26310DJ & Connection of an external system controller IRMD26310DJ is configured by default to use the PWM signals from the on-board IRMCF341 controller for the IRS26310DJ HVIC. The default configuration connects the IRMCF341 digital control IC to the IRS26310DJ by shorting pins 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18 on connector P1 shown in Figure 7. Since the IRS26310DJ is based on Active High logic, the PWM inputs to the HVIC in IRMD26310DJ are connected to GND using pull-down resistors (R26 to R32). An external controller can easily be invoked for driving the IRS26310J by removing the shorting connections on the 20 pins DIL connector P1 and connecting the external PWM signals to the odd numbered pins on P1. It is reiterated that the correct PWM inputs that is appropriate for the “Active High” logic of IRS26310DJ must be maintained. Figure 7: 20-pin connector P1 www.irf.com © 2008 International Rectifier 10 IRMD26310DJ Test Points for Investigation The reference design is provided with ample test points to probe the different pins of the gate driver IC and inverter circuit. The following table provides a summary of the most useful test-points around the IRS26310DJ HVIC and their associated functionality. Test Point # Test Point Name Remark TP28, 29, 30 U, V, W Motor Phase nodes (also negative terminals of bootstrap supply voltage) TP37, 38 & 39 VB3, VB2, VB1 Boot-strap supply voltage positive terminal TP9, 10, 11 UH, VH, WH PWM input to high-side channels of HVIC (HIN1, HIN2 & HIN3) TP31, 32, 33 UG, VG & WG Gate of high-side IGBTs TP7, 8, 9 UL, VL, WL PWM input to low-side channels of HVIC (LIN1, LIN2 & LIN3) TP34, 35, 36 UG/, VG/, WG/ Gate of low-side IGBTs TP24 COM Common emitter of low-side IGBTs (also Positive terminal of current shunt resistor) TP22 GK FAULT / EN pin of IRS26310D (also Input to IRMCF341 GATEKILL pin) TP2 IFB Motor current feedback TP4 DCP DC Bus TP14, 15, 25, 26, 27 GND Logic ground of IRS26310D (VSS pin) & DC Bus return TP103 VCC VCC pin of IRS26310D Table 2: List of Test Points www.irf.com © 2008 International Rectifier 11 IRMD26310DJ IRMD26310DJ – Operating Instructions The following hardware is supplied with the IRMD26310DJ reference design kit • IRMD26310DJ board with heat sink • GUI Software CD-ROM • PC USB-serial cable & driver CD-ROM Visually inspect IRMD26310DJ board to check for loose wiring, loose or damaged components or other abnormalities before proceeding. STEP 1: Software Installation The reference design kit is supplied with IRMD26310 GUI v1.0 software intended to support the evaluation of IRS26310DJ HVIC. The on board digital control IC (IRMCF341) generates the inverter PWM signals and can run a three phase induction motor using open loop V/F or Volts-per-Hertz control. This software is the GUI that allows the specification of the motor, inverter and system parameters. The software tool is distributed on a CD-ROM. Load the CD into the CD-ROM drive on a PC and if installation does not start double-click on the .exe installation file. The automated procedure installs all necessary software and documentation on the PC. The default location for the installation is “C:\Program Files\IR\IRMD26310DJ”. STEP 2: Test Bench Connection 1. Connect the ac power cables to Earth (E), line (L) and neutral (N) terminals of J1 connector. Prepare a power contactor switch rated at 250V/10A in series with AC power cables if necessary. ! ATTENTION: Turn off or unplug the power before making any connections to board. All circuits on board must be considered as ‘live’ with respect to the safety earth so please use extreme caution when making connections to circuit board. It is recommended to isolate the oscilloscope ground when making circuit waveform measurements. 2. Connect the motor windings to the U/V/W terminals of connector J1. If needed, connect the motor frame to the Safety Earth connection available on the E terminal of connector J1. NOTE: GND terminal of connector J1 is NOT to be used for the purpose of safety grounding. 3. Connect the RS-232 cable between the DB-9 connector J6 on IRMD26310DJ board and an available COM port (USB port) on your PC. The RS-232 serial connector is galvanically isolated from the circuit board ground so the user can safely connect a PC to the board. Figure 8: Test bench connection www.irf.com © 2008 International Rectifier 12 IRMD26310DJ Phase U To PC Phase V To Motor Phase W DC Bus GND Neutral Line Earth To AC Input Figure 9: Board connections E Safety Earth (connected to the heatsink) L AC line input N AC neutral input GND DC bus ground DCP Positive DC bus U motor U phase V motor V phase W motor W phase Figure 10: 8-pin connector J1 ! ATTENTION: The GND terminal of connector J1, called DC Bus Ground, is biased to the negative DC bus voltage potential of IRMD26310DJ, which connects to the ac power line input via the input rectifier. The GND terminal is NOT to be confused with safety ground of the system. Instead, the E terminal of connector J1, called Safety Earth, is to be used for purpose of safety grounding. Failure to follow these instructions can result in personal injury or death. STEP 3: Powering the Board Connect the power cables to 220VAC mains and turn-on the power switch. There are 2 on-board LEDs for diagnostic purposes as shown in Fig.11. 1. Check if LED2 is lit in red after you apply AC power. LED2 is connected to the dc bus and indicates that power is connected to the board and the on-board switching mode power supply is active. NOTE: Never attempt to service the board or engage/disengage any connections when LED2 is lit since it indicates the presence of high-voltages on the board. 2. Check if LED1 is a slowly flashing green. LED1 is driven by the digital control IC IRMCF341 controller. It is lit red when a fault is detected and slowly flashes green when IRMCF341 is in proper operational status. If LED1 is lit red after powering the board then it indicates one of the following: i. Under-voltage fault: This occurs if rectified DC bus voltage is less than 120V; Check DC Bus & AC input voltage levels and ensure DC bus is greater than 120V. Then proceed to Step 4. LED1 will be a flashing green once Step 4 is completed. ii. Over-voltage fault: This occurs if rectified DC bus voltage is greater than 360V; Check DC Bus & AC input voltage levels and ensure that DC bus is less than 360V. Then proceed to Step 4. LED1 will be a flashing green once Step 4 is completed. iii. Reference Design Configuration Error: Contact IR Support. www.irf.com © 2008 International Rectifier 13 IRMD26310DJ LED1 LED2 Figure 11: Location of diagnostic LEDs in IRMD26310DJ STEP 4: Running the Software GUI Step 4a: Start the GUI software program on PC Start the GUI Software by clicking the desktop icon or double-clicking .exe file. Figure 12: Software GUI before establishing communication between PC & IRMD26310DJ Note the following: www.irf.com © 2008 International Rectifier 14 IRMD26310DJ - All 3 icons in System Status section of GUI in the top-right corner of the GUI (Connection Status, Fault Status & Configuration Status) are yellow in color. At the bottom of the GUI the messages “No COM Port Set” & “Disconnected” are displayed All buttons in the Controls section of GUI are disabled Step 4b: Selecting the COM port (RS-232) The software on the PC communicates with the digital control IC on-board using a COM port. It is necessary to select the COM port to which the USB cable is connected to run the GUI software. COM port can be selected by clicking on “COM Settings” at the bottom-left of the GUI window and selecting one of the options. Figure 13: COM port selection When the correct COM port has been selected and communication is successfully established, - the “Connection status” & “Fault status” icons in the System Status section of the GUI should change colors from yellow to green - the Monitor section icons should change color from yellow to green and provide real time information regarding the item being monitored i.e. DC Bus Voltage & Output current - the “Fault Clear” & “Configure” buttons in Controls section are enabled and - the messages “COM# Set” (where # is the appropriate COM port number) and “COM Port UP” are displayed at the bottom. Figure 14: Software GUI after establishing communication between PC & IRMD26310DJ www.irf.com © 2008 International Rectifier 15 IRMD26310DJ Step 4c: Configuring the Hardware After the selection of inverter and motor parameters on the GUI click on the ‘Configure’ button to load them to the digital control IC on the IRMD26310DJ board. This step is absolutely necessary before the motor can be started. Please refer to “Software GUI Reference Guide” section for more information about GUI parameters and the associated system implications. Upon successful configuration, the - the “configuration status” icon in the System Status section of the GUI should change colors from yellow to green - the “Start” button in Controls section is enabled NOTE: Remember to press the configure button every time after a change is made to any GUI parameter. NOTE: The DC bus voltage must remain constant after pressing the configure button, otherwise the control algorithm will not operate as expected. Remember to press the configure button after every time the DC bus level is altered. Figure 15: Software GUI after successful configuration of IRMD26310DJ www.irf.com © 2008 International Rectifier 16 IRMD26310DJ Step 4d: Starting, Running & Stopping the Motor - To start the motor, press the “Start” button in the Controls section. The motor will start and accelerate to the specified rotation speed. Further, the “Start” button in the Controls section of the GUI will toggle into a “Stop” button Figure 16: Software GUI while running the motor using IRMD26310DJ - While running, the motor speed can be changed real-time by using the slide bar to set the new speed. To stop the motor, simply press the “Stop” button. The motor will coast to a full stop. Further, the “Stop” button will toggle back to “Start”. Software GUI Fault Handling Instructions A fault situation may be triggered either by the software GUI or hardware (digital control IC). Please refer to the “Software GUI Reference Guide” section for more information about the fault conditions that can be encountered during operation. In both cases, when a fault is encountered during motor operation, the GUI immediately stops the motor. Further, - the “Fault Status” icon in System Status section changes to red; In addition, if the fault condition is related to any of the Monitors, then the appropriate Monitor icon also changes color to red - the “Start” button in Controls Section is disabled - the fault condition is displayed at the bottom of the GUI Please refer to “Software GUI Reference Guide” section for a complete list of faults that may be encountered during operation. Figure 17: Software GUI during 2 different fault situations To clear the fault and restart motor, the following actions are performed in the specified sequence - press the “Fault Clear“ button in Controls Section; the “Fault Status” icon & the respective system monitor icon in System Status section then change from red to green - Reconfigure the motor as outlined in Step 4b - Proceed to running the motor as outlined in Step 4c www.irf.com © 2008 International Rectifier 17 IRMD26310DJ How to Trigger IRS26310DJ DC Bus Overvoltage Protection The IRS26310D gate driver IC monitors the DC bus voltage to prevent it from charging to an unsafe voltage level during regenerative braking when used to drive permanent magnet motors. The DC bus voltage is scaled down using a resistor divider and communicated to the DCBusSense pin. When the voltage on the DCBusSense pin goes above a maximum threshold (VDCBUSOV+) an over-voltage condition is sensed and it forces IRS26310DJ into zero vector mode. In this mode the driver turns-on all low side transistors and turnsoff all high side transistors irrespective of the PWM input commands from digital control IC. The divider network R35, R36 and R37 in IRMD26310DJ sets DC bus overvoltage protection level to 386V. Figure 18: IRS26310 DC Bus Overvoltage Protection Feature Since IRMD26310DJ will be used to drive an Induction motor, which does not engage regenerative braking like a permanent magnet motor, it is not straightforward to trigger the DC bus overvoltage protection of the driver IC. However, the following suggestions are provided i. The Decel Rate parameter in software GUI is used to define the ramp-down characteristic of the induction motor during halting. A smaller value halts the motor more abruptly. By engaging an abrupt stop of the induction motor when running at a high speed under loaded condition, it is possible to create a DC bus voltage overshoot during motor stop. Zero vector insertion is triggered when the overshoot exceeds 386V. For more information regarding the Decel Rate parameter please refer to “Software GUI Reference Guide” section. Further, by changing resistor R37, it is also possible to decrease the DC bus overvoltage level at which the protection is triggered to suit other test conditions such as AC input voltage level, motor speed, load-under-test etc. For example, in Fig.19 where zero-vector insertion is activated during motor stop, the reference design was modified to trigger DC Bus overvoltage protection feature at 275V. DC Bus Voltage Motor Current LO1 Zero-vector insertion & LO turn-on ZOOM-IN ii. Figure 19: Zero vector insertion during IRS26310DJ DC Bus overvoltage protection The DC bus overvoltage feature can also be engaged in a “static” test (motor not running) in order to verify the IC functionality. To do this the AC input voltage level can simply be increased high enough to result in a rectified DC bus voltage greater than 386V; However, in this method, running the motor will not be possible since software GUI will trigger a “DC Bus Voltage Level fault”. www.irf.com © 2008 International Rectifier 18 IRMD26310DJ IRMD26310DJ – Software GUI Reference Guide Motor parameters • • • • • • Number of poles – The number of poles defines the ratio of the electrical to mechanical frequency in the induction motor (# of poles = Electrical Frequency/Mechanical Frequency). This is selected from the drop down menu in the GUI. Only even number values are listed in the drop down menu since the motor poles come in pairs. Max speed – This is the maximum speed that the motor can run. The motor speed cannot be set faster than this value. This is entered in revolutions per minute (RPM). This parameter can be obtained from the motor nameplate. Min speed – This is the minimum speed that the motor can run. The speed cannot be set lower than this value. This is entered in revolutions per minute (RPM). Current Limit – This is the maximum RMS current (phase current in the motor) that the system will allow in the motor before the GUI triggers a fault and stops the motor. This is entered in amperes (A). This parameter can be obtained from the motor nameplate. Volts – This is the rated RMS voltage (L-L) of the induction motor. This parameter is the voltage used in the V/Hz control algorithm. This is entered in Volts (V). This parameter can be obtained from the motor nameplate. NOTE: When the configure button is pressed this value is sampled along with the current DC bus. The DC bus must remain constant after pressing the configure button, otherwise the control algorithm will not operate as expected. Base Speed – This is the rated electrical frequency for running the induction motor. This parameter is the Hertz value used in the V/Hz control algorithm. This is entered in Hz. This parameter can be obtained from the motor nameplate. Inverter parameters • Carrier frequency - User selectable input of PWM frequency of inverter. This is entered in KHz in the range from 5kHz to 35khz. • Dead time – The dead time that will be present between switching high and low side IGBTs. This is entered in µs. Typically, deadtimes are less than 1usec. System Status • Connection status – Indicates if the connection between software and IRMCF341 is working and active. Green indicates successful connection, while yellow indicates lack of connection. Other System status icons also remain yellow when there is no connection. • Fault Status – Indicates if any faults are present in the system. Green indicates fault-free status while red indicates occurrence of a fault. The fault condition is displayed at the bottom of the GUI and the associated Monitor icon is also lit red, if applicable. Faults can be cleared by pressing the Fault Clear button. If the fault remains even after pressing the Fault Clear button then it indicates that the underlying fault condition is continuing to persist. Table 3 shows a list of all the faults that can be encountered. • Configure Status – Indicates if any parameters have been modified since the last configure. If this indicator is yellow, the configuration button should be pressed again prior running the motor. It is recommended to press the configuration button every time before starting and running the motor. Control • Fault clear – This button will clear all of the faults present in the system. If the fault remains even after pressing this button it indicates that the fault situation is continuing to persist. This button will be disabled when a PC-to-hardware connection is not present and when the motor is running. Shutdown power and restart GUI to resume operation. www.irf.com © 2008 International Rectifier 19 IRMD26310DJ • • Configure - This button will configure the hardware with the parameters that have been selected in the GUI. This step is not done automatically. Remember to configure the hardware every time a parameter is altered or DC bus voltage level is changed. This button will be disabled when a PC-tohardware connection is not present and when the motor is running. Shut-down power and restart GUI to resume operation. Start/Stop – This toggle-type button starts and stops the motor. During motor-start, an acceleration control gradually ramps the motor speed to the value in “Requested Speed” field. Fault Name Overvoltage Fault Fault Type (source) Hardware Generated (by Digital IC) Undervoltage Fault Hardware Generated (by Digital IC) DC Bus Voltage Level Fault Gatekill Fault Overcurrent Fault Hardware Generated (by Digital IC) Hardware generated (by HVIC) Software Generated System Error Software Generated Explanation of Fault Fault Trip Level Indicates DC bus over-voltage condition at system power-up (NOTE: this fault occurs only during power up, when GUI is still unconfigured) Indicates DC bus voltage under-voltage condition at system power-up (NOTE: this fault occurs only during power up, when GUI is still unconfigured) Indicates either a DC bus over-voltage or under-voltage condition (NOTE: this fault occurs after GUI has been configured) Indicates ITRIP fault or VCC UVLO fault occurring in IRS26310DJ; Gatekill fault is triggered by FAULT / EN pin of IRS26310D Indicates that motor current fault DC Bus Voltage > 360V Indicates out-of-bounds errors, contact IR support Table 3: List of faults issued by software GUI DC Bus Voltage < 120V DC Bus Voltage > 360V OR DC Bus Voltage < 120V VCC < 8.2V (Typ) AND/OR V(R60) > 14A (Typ) RMS Motor Current calculated by GUI > “Current Limit” - Monitors • DC bus voltage – The instantaneous voltage of the DC bus. The over-voltage fault is encountered if the DC bus increases beyond 360V. The under-voltage fault is encountered if DC bus is less than 120V. • Output current – The rms motor current calculated by software. It is dependent on the shunt resistor value defined on the system parameter. The over-current fault is encountered if the calculated value exceeds the “Current Limit” parameter. Speed Control • The START button in the GUI starts the motor and gradually ramps the motor speed to the specified value in “Requested Speed” field. In addition, the GUI has a slider to adjust the motor if it is already running. An acceleration control is included to gently accelerate to the requested speed and is not user definable. • Decel Rate - DecelRate parameter is used to define the ramp-down characteristic of the motor during halting. This value is entered in s (seconds) between 0.1 and 10. This parameter is manipulated along with the motor speed, load and rectified AC line voltage to simulate DC bus overvoltage condition during motor stop. A smaller Decel Rate value brings the motor to halt faster and will cause a higher voltage overshoot. In the IRMD26310DJ default configuration, when DC bus voltage exceeds 386V, the zero-vector mode of IRS26310DJ is activated. NOTE: The zero-vector insertion based DC bus overvoltage protection feature is triggered exclusively by IRS26310DJ and not by the digital control IC or software GUI. Hence no specific fault flags are displayed by GUI. However, since DC bus voltage has to exceed 360V before hitting the 386V limit when zero-vector insertion can occur, “DC bus Voltage Level Fault” message is displayed in GUI. www.irf.com © 2008 International Rectifier 20 A B C EARTH LINE NEUTRAL GND DCP W V U 1 JK55B-100-8 1 2 3 4 5 6 7 8 1 4 1 U TP28 1 W TP30 V 1 TP29 GND C37 100pF Itrip 2 VCC_short VCC VCC_short R69 DNI R70 DNI C38 0.01uF 1 2 3 4 VCC1 DNI Q8 C24 10uF,25V 1M R39 8 7 6 5 IFB C20 0.1uF R71 DNI TP2 IFB 3 VCC RCIN VCC1 C17 DNI R124 R73 R72 0.030, 3W R60 0 DNI DNI C18 DNI VCC IFB 16 17 14 13 12 11 10 9 8 7 6 15 3 VCC1 1 2 3 4 VSS VCC DNI Q9 RCIN Itrip FLT/EN Lin3 Lin2 Lin1 Hin3 Hin2 Hin1 DCBSns DCB+ U5 IRS2631 R123 0 VCC1 R122 DNI TP24 COM 20K GATEKILL PWMWL R38 PWMVL TP22 GK PWMUL PWMWH PWMVH PWMUH C45 10uF,10V R26 R27 R29 R30 R31 R32 4.7k 4.7k 4.7k 4.7k 4.7k 4.7k C36 2200pF R37 22.0K R36 1.00M DCBSns TP27 GND R28 4.7k CAP1 TP26 GND TP15 GND C44 0.1uF +3.3V + 470uF, 450V DCP TP25 GND TP14 GND CY2 2.2nF BR1 8GBU06 C34 0.1uF,630V R35 1.00M 1 J1 CY1 2.2nF 2 3 PTC/N5RL20 1 T1 LCL-UF1125 CX2 0.1uF 250VAC 1 2 POWER STAGE 1 3 TP4 DCP 1 CX1 0.1uF 250VAC 4 + 1 t 1 D 20 4 VCC1 C27 2.2uF, 25V DNI 21 LO3 22 LO2 1 TP39 DNI C26 2.2uF, 25V VB3 HO3 D6 D7 C25 VB1 2.2uF, 25V VB2 HO2 VB1 HO1 DNI 23 LO1 29 30 31 35 36 37 41 42 43 8 R74 7 6 5 COM LO3 LO2 LO1 VS3 HO3 VB3 VS2 HO2 VB2 VS1 HO1 VB1 DNI R17 VB2 R119 33 R120 R121 VCC1 MBR0530T1 33 D14 R99 UG1 D10 R62 VG 33 R101 R63 D11 WG 33 R118 /WG /VG /UG 1 TP34 /UG MBR0530T1 33 MBR0530T1 33 R66 33 D13 33 TP31 UG MBR0530T1 33 MBR0530T1 33 R65 33 D12 R64 D9 R61 MBR0530T1 33 D8 TP38 DNI TP37 VB3 1 4 1 1 3 1 2 TP32 VG Q1 Q4 /VG 1 TP35 1 IRGIB10B60KD1 1 IRGIB10B60KD1 1 1 1 1 5 5 TP33 WG Q2 Q5 /WG 1 TP36 1 IRGIB10B60KD1 1 IRGIB10B60KD1 1 2 3 2 2 3 2 2 3 2 3 21 3 www.irf.com 3 1 U Q6 IRGIB10B60KD1 Q3 IRGIB10B60KD1 V W 6 6 A B C D IRMD26310DJ IRMD26310DJ – Circuit Schematics Figure 20: IRMD26310DJ power stage circuit schematic © 2008 International Rectifier A B C D 0.1uF 0.1uF R68 R83 0 R80 R34 1.00M C67 0.1uF 0.1uF R59 1.00K 1% R33 2.00K 1% 1 0.1uF C68 R20 1 2 3 4 5 6 0.01uF C97 R3 R2 DNI 0 5.11K 470 C4 2 15pF CL2 0.1uF C12 470 R85 C43 2200pF 33pF, 50V R84 470 3 Rd 10 11.8K TP42 AREF 11.8K C5 10uF,10V + R79 R76 R21 4.87K R77 +3.3V C14 0.1uF 5.11K 2 4 6 8 10 12 14 16 18 20 0.01uF C99 ? 1 3 5 7 9 11 13 15 17 19 P1 R82 C35 0.01uF C98 PRPN061PAEN J5 GATEKILL PWMWL PWMWH PWMVL PWMVH PWMUL PWMUH 1.00M +3.3V 1.00K R81 0.01uF C10 47pF, 50V 0.01uF C9 1.00K 0.01uF C95 DC Bus Feedback GATEKILL PWMWL PWMWH PWMVL PWMVH PWMUL PWMUH DCP C66 +3.3V C23 10nF ,50V 1.8V DCP From Shunt Resistor IFB 0 0.01uF C96 0.01uF C8 Current Shunt Feedback From Shunt Resistor R67 C6 C3 GND 1.8V 0.1uF C63 2 1 TP8 WL TP23 IFBO 470 R86 TP10 VH Rf 1M 1 TP9 WH 470 AREF IFB+ IFBIFBO TP7 VL AIN0 AIN1 AIN2 AIN3 AIN4 AIN5 AIN6 R91 470 29 27 33 34 35 36 37 41 42 43 44 45 46 47 24 31 30 32 10uF,10V C33 100 pF TP11 UH 1 2 CMEXT 28 U2-1 U2-2 + C31 15pF CL1 CM309S4.000MABJTR CR1 R90 TP6 UL 1 1 4 1 0.1uF 1 C62 1 AIN1 AIN2 AIN3 AIN4 AIN5 AIN6 GATEKILL PWMWL PWMWH PWMVL PWMVH PWMUL PWMUH AIN0 IFB+ IFBIFBO AREF CMEXT XTAL0 XTAL2 1.8V 3 3 +3.3V 1 2 IRMCF341 SCL/SDI-SDO SDA/CS0 P3.0/INT2/CS1 P3.1/AOPWM2 P3.2/NINT0 P3.3/NINT1 P3.5/T1 P2.0/NMI P2.1 P2.2 P2.3 P2.4 P2.5 P2.6/AOPWM0 P2.7/AOPWM1 P1.0/T2 P1.1/RXD P1.2/TXD P1.3/SYNC/SCK P1.4/CAP P1.5 P1.6 P1.7 P5.1/TMS P5.3/TDI TCK P5.2/TDO RESET TSTMOD U2 SCL SDA 55 56 C46 0.1uF C32 0.1uF P3.0 DAC2 P3.2 P3.3 P3.5 48 49 50 51 52 +3.3V +3.3V +3.3V C22 10uF,10V C21 10uF,10V R11 1K P2.0 P2.1 P2.2 VCC_short P2.4 P2.5 DAC0 DAC1 14 15 16 17 18 19 20 21 10K TP12 RST 2 C84 10uF, 10V 4 R12 1K R6 R54 U3 SN74LVC1G14DCK +3.3V R43 R1 4.7K +3.3V RST TSTMOD C83 0.1uF P1.0 RX1 TX1 P1.3 P1.4 P1.5 P1.6 P1.7 3 4 3 4 5 6 7 8 9 10 57 59 60 58 62 61 KT11P3JM S1 4 1 0.1uF 1 4 TP5 SCL 0 0 2 8 7 6 5 8 7 6 5 A0 A1 NC GND 1 2 3 4 1 2 3 4 VCC_short A0 A1 NC GND AT24C02BN VCC WP SCL SDA U20 TMS TDI TCK TDO +3.3V C40 0.1uF +3.3V C39 0.1uF DBRST R18 0 R14 0 R19 0 R16 0 +3.3V +3.3V nRST 1K R15 R52 100 3 R53 100 LNJ115W8ARA AT24C512BN VCC WP SCL SDA U17 R42 10K R89 4.7K LED1 1 +3.3V R87 4.7K GREEN RED R88 4.7K 4 B Q7 MMBT3904LT1 R25 4.7K +3.3V C E C61 1 25 AVDD 11 22 38 VDD2 VDD2 VDD2 VSS VSS VSS VSS 12 23 39 53 2 PLLVDD 13 VDD1 40 54 VDD1 VDD1 63 PLLVSS 64 5 3 1 AVSS 26 1 22 16 15 14 13 12 11 10 9 1 2 3 4 VDD2 VIA VOB GND2 VDD1 GND1 VIA VIB VIC VOD VE1 GND1 5 R40 R55 DAC2 DAC1 DAC0 0 0 ADUM1401BRW VDD2 GND2 VOA VOB VOC VID VE2 GND2 ISO3 ADUM1201BR VDD1 VOA VIB GND1 ISO4 5 1 2 3 4 5 6 7 8 8 7 6 5 TX1 RX1 5V_I C42 0.1uF R58 10K JP1 +3.3V 5V_I R24 10K JP2 +3.3V R22 0 C69 0.1uF 1K 6 6 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 R75 nRST_I TMS_I TDI_I TCK_I TDO_I R7 4.7K DBRST_I C65 10uF, 10V R8 R10 R13 4.7K 4.7K 4.7K C41 0.1uF R57 0 5V_I 21 www.irf.com 21 1.8V 3M 2510-6002UB DBRESET TMS TDI TCK TDO TRIG VCC GND GND J7 PRPN051PAEN 1 2 3 4 5 J3 PRPN082PAEN 6 2 10 4 8 5 9 1 3 7 J11 A B C D IRMD26310DJ Figure 21: IRMD26310DJ Digital Control & Communications Circuit Schematic © 2008 International Rectifier A B C MH2 TP18 DA0 DB9RF 1 2 3 4 5 6 7 8 9 MH1 J6 TP19 DA1 1 23 TP20 DA2 1 www.irf.com 1 1 0.01uF C91 0.01uF C90 0.01uF C89 1K R50 1K R47 1K R46 D/A FILTER VSS 1 TP1 0.01uF C94 0.01uF C93 0.01uF C92 5V_I 7 3 0 0 DNI R44 R56 R78 1K R51 1K R49 1K R48 0 R41 2 DAC2 DAC1 ROUT DIN C2- C2+ C1- C1+ GND VCC DAC2 DAC1 DAC0 MAX3221CDBR RIN DOUT INVALID FORCEOFF FORCEON EN V- V+ U4 DAC0 8 13 10 16 12 C51 0.33uF 1 C50 0.33uF RS-232 DRIVERS / RECEIVERS 2 9 11 6 5 4 2 14 15 TP16 5V_I 1 D 1 C52 0.1uF FID4 1 1 1 FID3 3 5V_I C29 0.1uF FID2 1 FID1 RX_I TX_I C54 0.33uF C53 0.047uF 5V_I 3 1 2 3 4 VDD2 VIA VOB GND2 1 FID6 1 FID5 ADUM1201BR VDD1 VOA VIB GND1 ISO5 8 7 6 5 C30 0.1uF +3.3V 4 TX1 RX1 4 A B C D IRMD26310DJ Figure 22: IRMD26310DJ RS-232 Drivers & Receivers Circuit Schematic © 2008 International Rectifier A B C 1 DCP LED2 LTL-16KE 75K,1W R5 75K,1W C100 100uF,25V VCC TP103 VCC C107 100pF IN 1 FID102 1 FID100 1 NJM78M15FA 1 OUT U100 10nF,50V R108 47 C110 IS C111 100 R109 R116 75K,1W 470pF,50V 3 6 220uF,35V C101 TP100 GND RT/CT VREF COMP 10nF,50V 4 8 OUT 200K,1W R115 UC3842D8 VFB U103 C109 R107 2.00K FID103 2 2 330pF,50V 1 68K 0.1uF,50V 1 3 R105 5.1K R106 C108 R114 200K,1W C117 C116 0.1uF,630V FID101 R104 1.6K 47uF,35V C115 1 TP106 DCP 7 VCC 3 D5 10MQ100N D2 10MQ100N R110 22K R117 75K,1W 3 1K R111 1 US1JDICT D3 2 1 4 3 330pF,50V 5 C102 330 R100 100mA R112 1.0,1W IRFBG30 Q100 C118 270pF,1KV T100 EE16 FLYBACK POWER SUPPLY 2 3 R4 1 DCP GND 2 GND 5 1 6 VSS 1 7 8 9 10 D1 E100 1 1 Vin U31 L100 10uH, 3A 4 R102 1M P la ce a p lat ed t hro ugh ho l e C104 330uF, 25V 10 R103 1000uF,16V C112 D4 6TQ045 10MQ100N 3 C19 330pF,50V 330 R9 4 3 GND 8 7 4 3 5V_I 5 1.24 x ( 1 + 110/243) = 1.8 IRU1208CS GND GND ADJ GND VOUT FLAG 1k R113 VIN C105 TP13 330uF, 25V VSS 6 5 1 2 U1 C114 470uF,16V f or f lyi ng l ead con nec tion Vout LM340T-5 C1 68uF,16V C113 470uF,16V 5 R23 243 TP101 GND TP17 GND R45 110 TP107 3.3V 1 1 1 2 GND 24 2 www.irf.com 1 TP3 1.8V C2 68uF,16V 1APeak 200mA ave 1.8V C16 10uF,10V +3.3V 1 D 1 6 6 A B C D IRMD26310DJ Figure 23: IRMD26310DJ DC-DC Converter Low Voltage Power Supply Circuit Schematic © 2008 International Rectifier IRMD26310DJ IRMD26310DJ – Bill of Materials # COMPONENT DESCRIPTION 1 2 PCB CAP THR, 0.1uF 300VAC 20% X1 3 CAP SMT, 0.1uF 0805 CER 50V 10% X7R 4 CAP THR, 0.1uF CER,630V 5 6 QTY MANUFACTURER & PART# PCB, IRMD2631-R1.3 Panasonic ECQ-U3A104MG DIGIKEY P11116-ND DESIGNATOR 1 2 CX1,CX2 1 C117 2 C34,C116 CAP SMT, 0.01uF 0603 CER 50V 10% NPO/COG 14 C8-C10,C89-C99 CAP SMT, 0.1uF 0603 CER 50V 10% X7R 20 C3,C6,C12,C14,C29,C30,C32,C3 9-C42,C44,C46,C61-C63,C66C69 7 CAP SMT, 0.1uF 0805 CER 50V 10% X7R 3 C20,C52,C83 8 CAP SMT, 10000pF 0805 CER 50V 10% X7R 1 C38 9 CAP SMT, 0.33uF 0805 CER 50V 10% X7R 3 C50,C51,C54 10 CAP SMT, 47nF 0805 CER 50V 10% X7R 1 C53 11 CAP THR, 2200PF 250VAC 20% Y2/X1 2 CY1,CY2 12 CAP SMT, 2.2uF 0805 CER 25V 10% X7R 3 C25-C27 13 CAP SMT, 10000pF 0805 CER 50V 10% X7R 3 C109,C110,C23 14 CAP SMT, 10uF 3216 (A) TANT 16V 10% 8 C5,C16,C21,C22,C31,C45,C65,C 84 15 CAP SMT, 10uF 6032 TANT 25V 10% 1 C24 16 CAP SMT, 15pF 0603 CER 50V 5% NPO/COG 2 CL1,CL2 17 CAP SMT, 33pF 0603 CER 50V 5% NPO/COG 1 C4 18 CAP SMT, 47pF 0603 CER 50V 5% NPO/COG 1 C35 19 CAP THR, 47uF, AL ELEC, 35V 2mmLS 1 C115 20 CAP SMT, 68uF 7343 TANT 16V 20% 2 C1,C2 21 CAP SMT, 100pF 0603 CER 50V 5% NPO/COG 1 C33 22 CAP SMT, 100pF 0805 CER 50V 5% NPO/COG 2 C37,C107 23 CAP THR, 100uF, AL ELEC, 25V 2mmLS 1 C100 24 CAP THR, CAP 270PF 1KV CERAMIC DISC GP 10% 1 C118 25 CAP THR, 220uF AL ELEC, 35V POL, (0.140"ls/3.5mm) 1 C101 26 CAP SMT, 330pF 0805 CER 50V 10% X7R 3 C19,C102,C108 27 CAP THA, 330uF, AL ELEC 25V 2 C104,C105 28 CAP SMT, 470pF 0805 CER 50V 10% X7R 1 C111 29 CAP THR, 470uF, AL ELEC 16V 20% 2 C113,C114 30 CAP THR, 1000uF, AL ELEC 16V 20% 1 C112 31 CAP SMT, 2200pF 0805 CER 50V 10% X7R 2 C36,C43 32 CONN, HDR, 2x10 PIN 0.025" SQ POST GOLD (0.100"/0.230") 1 P1 33 CONN, SHUNT, 2-PIN SHORTING SHUNT 10 @P1 34 CAP THR, 470uF,ELEC 450V 20% 1 CAP1 35 RES SMT, 0-OHM 1/8W 5% 0805 18 R2,R6,R14,R16,R18,R19,R22,R4 0,R41,R44,R54,R55,R56,R57,R6 7,R68,R123,R124 36 RES SMT, 0.03-OHM 3W 1% 1225 1 R60 37 RES SMT, 1-OHM 1W 5% 2512 1 R112 38 RES SMT, 1.0K-OHM 1/8W 1% 0805 15 R59,R80,R83,R11,R12,R15,R46R51,R75,R111,R113 39 RES SMT, 1.0M-OHM 1/8W 1% 0805 4 R20,R34,R39,Rf 40 RES SMT, 1M-OHM 1/4W 1% 1206 3 R35,R36,R102 Panasonic ECQ-E6104KF Digikey EF6104-ND Panasonic ECK-NVS222ME DIGIKEY P11420CT-ND KEMET T491A106K016AT T491A106K016AG DIGIKEY P5164 PANASONIC EEU-FC1V221L DIGI-KEY P10296-ND SAMTEC TSW-110-07-S-D Panasonic EET-UQ2W471DA DIGIKEY P11951-ND www.irf.com © 2008 International Rectifier 25 IRMD26310DJ # COMPONENT DESCRIPTION QTY MANUFACTURER & PART# DESIGNATOR 41 RES SMT, 1.6K-OHM 1/8W1% 0805 1 42 RES SMT, 2.0K-OHM 1/8W 1% 0805 2 R33,R107 43 RES SMT, 4.7K-OHM 1/8W 1% 0805 16 R1,R7,R8,R10,R13,R25-R32,R87R89 44 RES SMT, 4.87K-OHM 1/8W 1% 0805 1 R21 45 RES SMT, 5.1K-OHM 1/8W 1% 0805 1 R105 46 RES SMT, 5.11K-OHM 1/8W 1% 0805 2 R81,R82 47 RES SMT, 10-OHM 1/8W 1% 0805 1 Rd 48 RES SMT, 10-OHM 1/4W 5% 1210 1 R103 49 RES SMT, 10K-OHM 1/8W 1% 0805 4 R24,R42,R43,R58 50 RES SMT, 11.8K-OHM 1/8W 1% 0805 2 R77,R79 51 RES SMT, 20K-OHM 1/8W 1% 0805 1 R38 52 RES SMT, 22K-OHM 1/8W 1% 0805 2 R37,R110 53 RES SMT, 33-OHM 1/8W 1% 0805 12 R61-R66,R99,R101,R118-R121 54 RES SMT, 47-OHM 1/8W 5% 0805 1 R108 55 RES SMT, 68K-OHM 1/8W 1% 0805 2 R106 56 RES SMT, 75K-OHM 1W 5% 2512 4 R4,R5,R116,R117 57 RES SMT, 100-OHM 1/8W 1% 0805 3 R52,R53,R109 58 RES SMT, 243-OHM 1/8W 1% 0805 1 R23 59 RES SMT, 110-OHM 1/8W 1% 0805 1 R45 60 RES SMT, 200K-OHM 1W 5% 2512 2 R114,R1115 61 RES SMT, 330-OHM 1/4W 5% 1206 2 R9,R100 62 RES SMT, 470-OHM 1/16W 5% 0603 6 R76,R84,R85,R86,R90,R91 63 DIODE SCHOTTKY 100V 1.5A D-64 IR 10MQ100N 3 D1,D2,D5 64 65 66 67 68 69 70 IC DIGITAL ISOLATOR 4CH 16-SOIC IC DIGITAL ISOLATOR 4CH 16-SOIC IC SEEPROM 2K 2.7V SO-8 IC SEEPROM 512K 2.7V 8SOIC IGBT W/DIODE 600V 16A TO220FP DIGITAL CONTROL IC SOCKET SMT, 44L PLCC TIN SMD ANALOG DEVICE ADUM1201BR ANALOG DEVICE IC SMT, ATMEL AT24C02BN-SH IC SMT, ATMEL AT24C512BN-SH IR IRGIB10B60KD1 IR IRMCF341 TYCO/AMP 3-822516-1 DIGIKEY A97624CT-ND 2 1 1 1 6 1 NA ISO4,ISO5 ISO3 U20 U17 Q1-Q6 U2 U5 71 72 73 LDO REGULATOR IC IC SMT, MAX3221 RS-232 TRANSCEIVER 16L SSOP DIODE SMT, SCHOTTKY 30V 0.5A SOD-123 IR IRU1208CS MAXIM MAX3221CAE ON SEMI MBR0530T1G 1 1 6 U1 U4 D9-D14 74 TRANS SMT, NPN 40V 200mA SOT-23 ON MMBT3904LT1G DIODES MMBT3904-7-F 1 Q7 75 76 IC, MOSFET N-CH 1KV 3.1A TO-220AB IC 15V POSITIVE REGULATOR TO220F IR IRFBG30 NJR NJM78M15FA DIGIKEY NJM78M15FA-ND 1 1 Q100 U100 77 IC SMT, CUR-MODE PWM CONT 8-SOIC TI UC3842D8 DIGIKEY 296-11281-5-ND 1 U103 78 DIODE ULTRA FAST SW 600V 1A SMA DIODES INC US1J-13-F 1 D3 79 CONN, HDR, 1x2 BREAKAWAY, 0.025 SQ GD (0.100"/0.230") SAMTEC TSW-102-07-S-S TSW-102-07-G-S 2 JP1,JP2 80 CONN, HDR,2x5 3M .100" x .100" 4-Wall Header,Standard,Straight Through-Hole,10 Contacts,25106002UB 3M 1 J11 2510-6002UB www.irf.com R104 © 2008 International Rectifier 26 IRMD26310DJ # COMPONENT DESCRIPTION QTY MANUFACTURER & PART# DESIGNATOR 81 CONN, HDR,1x5 SULLINS PRPN051PAEN 1 J7 82 CONN, HDR,2x3 SULLINS PRPN032PAEN 1 J5 83 CONN, HDR,2x8 SULLINS PRPN082PAEN 1 J3 84 85 SINGLE SCHMITT-TRIGGER INVERTER CONN, 8P 10mm TI SN74LVC1G14DCK 1 1 U3 J1 86 SWITCH SMT, SWITCH SPST MOM KEY J-LEAD SMD ITT KT11P3JMDdigikey CKN9003CT-ND 1 S1 87 INDUCTOR MILLER_8103 1mH, 4.8A (BURNON LCL-UF1125) 1 T1 88 IC, REG, +5V, 1.0A, TO-220 NATIONAL SEMI LM340T-5.0 NOPB 1 ST Microelectroni L7805CV Digi-Key 497-1443-5-ND 89 LED SMT, 1.6x1.25mm BI-COLOR GREEN/ORANGE DIGIKEY 1 LED1 90 LED, T1 RED DIFF LITE-ON LTL-16KE DIGIKEY 160-1078-ND 1 LED2 91 MISC, TEST POINT MULIT PURPOSE MINI WHT KEYSTONE 5002 DIGIKEY 5002K-ND 44 92 DIODE SCHOTTKY 45V 6A D2PAK IR 6TQ045 1 D4 93 RECT BRIDGE GPP 600V 8A GBU DIODE GBU806 1 BR1 94 INDUCTOR HI CURRENT RADIAL 10UH JW MILLER 6000-100K-RC digikey M8616-ND 1 L100 95 OSC SMT, 4.0MHZ CRYSTAL 18PF CM309S Citizen CM309S4.000MABJTR digikey 300-8042-1-ND 1 CR1 96 CONN, D-SUB, 9P RECPT RT ANGLE W/ JACK SCREWS KYCON K22-E9S-NJ DIGI-KEY A23304-ND 1 J6 97 SMPS TRANSFORMER Precision 019-3214-03 1 T100 98 CURRENT LIMITER INRUSH GE sensing CL-60 Digikey KC006L-ND 1 RT1 99 COMPONENTS NOT POPULATED 17 C17,C18,R3,R17,R69R74,R78,R122,D6-D8,Q8,Q9 100 101 HIGH VOLTAGE GATE DRIVER IC HEATSINK 102 insulating films for TO-220 heat sink 103 104 HW, WASHER, M3, STEEL, SPLIT LOCK---LM7805 M3 * 8-3 M single screw, single-ended 3 M nuts, nylon, 6column-shaped isolation 105 M3 * 8-3 M single screw, single-ended 3 M nuts, copper / stainless steel, six-column-shaped isolation 106 HW, SCREW, #4-40 x 5/16" MACHINE PAN HEAD PHIL ZINC PLATED P11142CT-ND IR IRS26310DJPBF 1 ZHENJIANG HAOYANG HEAT SINK 1 COMPANY DS-480 ALLTHREAD 1929--3-A-01AAA U31 U5 6 @Q1-Q6 6 3 @Q1-Q6 1 ALLTHREAD 1940--3--8-2A21A-0.5 PITCH www.irf.com 11 © 2008 International Rectifier 27 IRMD26310DJ IRMD26310DJ Specifications TC = 25°C unless specified Parameters Input Power Voltage Frequency Input current Input line impedance 115V-230Vrms, -20%, +10% 50/60 Hz 4A rms @nominal output 4%∼8% recommended Output Power Watts 400W continuous power Vin=230V AC, fPWM=10kHz, fO=60Hz, TA=40°C, RthSA=1.0 °C/W, Vertically mounted to help air flow 3 Arms nominal, 9 Arms Overload RthSA limits ∆TC to 10°C during overload Host interface (RS232C) TXD, RXD 10V Typical 57.6 Kbps, single ended DC bus voltage Maximum DC bus voltage Minimum DC bus voltage 400V 120V Should not exceed 400V more than 30 sec Current feedback Current sensing device Resolution Latency 33 mΩ dc link shunt 12-bit 1 pwm cycle Single shunt reconstruction PCB design may reduce the resolution 386V Zero vector insertion by IRS26310DJ 14 A peak, typical Maximum 7 µsec 420 V 360 V 120 V Detection from shunt on negative DC bus line-to-line short, line-to-DC bus (-) short Zero vector insertion by digital controller Current Protection DC Bus Overvoltage Protection by IRS26310DJ Output current trip level Short circuit delay time Critical over voltage trip Over voltage trip Under voltage trip Power Devices IRGB10K60D1 x 6 Values Conditions o System environment Ambient temperature TA =40°C, RthSA=1.9 °C/W Rated for 10A @100 C case with 10µs short circuit withstand capability Integrated over-current protection 0 to 40°C 95% RH max. (Non-condensing) Table 4: IRMD26310DJ Electrical Specification The information provided in this document is believed to be accurate and reliable. However, International Rectifier assumes no responsibility for the consequences of the use of this information. International Rectifier assumes no responsibility for any infringement of patents or of other rights of third parties which may result from the use of this information. No license is granted by implication or otherwise under any patent or patent rights of International Rectifier. The specifications mentioned in this document are subject to change without notice. This document supersedes and replaces all information previously supplied. For technical support, please contact IR’s Technical Assistance Center http://www.irf.com/technical-info/ WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 Tel: (310) 252-7105 www.irf.com © 2008 International Rectifier 28