Application Note, V1.0, May.2007 AN2007-03 7ED020E12-FI-W2 Evaluation Board for EasyPIM®2B Modules with 2ED020I12-FI gate driver ICs Power Management and Drives Edition 2008-02-26 Published by Infineon Technologies AG 81726 München, Germany © Infineon Technologies AG 2008. All Rights Reserved. Attention please! THE INFORMATION GIVEN IN THIS APPLICATION NOTE IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY, CONDITION OR QUALITY OF THE INFINEON TECHNOLOGIES COMPONENT. THE RECIPIENT OF THIS APPLICATION NOTE MUST VERIFY ANY FUNCTION DESCRIBED HEREIN IN THE REAL APPLICATION. INFINEON TECHNOLOGIES HEREBY DISCLAIMS ANY AND ALL WARRANTIES AND LIABILITIES OF ANY KIND (INCLUDING WITHOUT LIMITATION WARRANTIES OF NON-INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF ANY THIRD PARTY) WITH RESPECT TO ANY AND ALL INFORMATION GIVEN IN THIS APPLICATION NOTE. Information For further information on technology, delivery terms and conditions and prices please contact your nearest Infineon Technologies Office (www.infineon.com). Warnings Due to technical requirements components may contain dangerous substances. For information on the types in question please contact your nearest Infineon Technologies Office. Infineon Technologies Components may only be used in life-support devices or systems with the express written approval of Infineon Technologies, if a failure of such components can reasonably be expected to cause the failure of that life-support device or system, or to affect the safety or effectiveness of that device or system. Life support devices or systems are intended to be implanted in the human body, or to support and/or maintain and sustain and/or protect human life. If they fail, it is reasonable to assume that the health of the user or other persons may be endangered. AP99007 Revision History: Previous Version: Page all 2007-09 none Subjects (major changes since last revision) First release Author : Zhang Xi (IFAG AIM PMD ID AE) We Listen to Your Comments Any information within this document that you feel is wrong, unclear or missing at all? Your feedback will help us to continuously improve the quality of this document. Please send your proposal (including a reference to this document) to: [[email protected]] V1.0 AN2007-03 Evaluation Board for EasyPIM 2B module ® Table of contents 1 Introduction ...................................................................................................................................5 2 2.1 2.2 2.3 Design features .............................................................................................................................6 Main features ..................................................................................................................................6 Pin assignment................................................................................................................................6 Mechanical dimension.....................................................................................................................7 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Application note ............................................................................................................................8 Switching behavior ..........................................................................................................................9 Over and short circuit current protection.......................................................................................10 Brake chopper...............................................................................................................................11 Over temperature protection .........................................................................................................11 /Fault output ..................................................................................................................................11 RMS current and DC link voltage limits ........................................................................................12 Indication of the surge current at turning on of the board .............................................................12 Cooling condition...........................................................................................................................12 4 4.1 4.2 4.3 Schematic, Layout and Bill of Material .....................................................................................12 Schematic......................................................................................................................................12 Layout............................................................................................................................................15 Bill of material................................................................................................................................16 5 How to order the evaluation board............................................................................................17 Part number explanation 7ED 020 E12 -FI -W2 Package EasyPIM®2B Functional isolation Suitable for 1200V module 2-Amp driver ICs 7 channel evaluation board Warnings The described board is an evaluation board dedicated for laboratory environment only. It operates at high voltages. There is no galvanic isolation between the high voltage side and any part of the board. This board must be operated by qualified, skilled personal conversant with all applicable safety standards. Application Note 4 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module 1 Introduction The Evaluation Driver Board 7ED020E12-FI-W2 for EasyPIM®2B modules as can be seen in Figure 1 was developed to support customers during their first steps designing applications with these modules. The basic version of the board is available from Infineon in small quantities. The properties of these parts are described in the datasheet chapter of this document whereas the remaining paragraphs provide information intended to enable the customer to copy, modify and qualify the design for production, according to his specific requirements. The design of the 7ED020E12-FI-W2 was performed with respect to the environmental conditions described as design target in the datasheet part. The requirements of RoHS compliance have been considered when components were selected. The design was tested as described in this documentation but not qualified regarding manufacturing and operation in the whole operating ambient temperature range or lifetime. The boards provided by Infineon are subjected to functional testing only. Due to their purpose Evaluation Boards are not subjected to the same procedures regarding Returned Material Analysis (RMA), Process Change Notification (PCN) and Product Withdraw (PWD) as regular products. See Legal Disclaimer and Warnings for further restrictions on Infineons warranty and liability. SAP No. 30378 Figure 1 The Evaluation Board 7ED020E12-FI-W2 with EasyPIM®2B mounted on the back side Application Note 5 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module 2 Design features The following sections provide an overview of the boards including main features, key data, pin assignments and mechanical dimensions. 2.1 Main features The Evaluation Board 7ED020E12-FI-W2 contains four coreless transformer ICs 2ED020I12-FI from Infineon and one Infineon EasyPIM®2B module, which contains a B6 diode rectifier, a brake chopper and an six IGBTs for the inverter. Figure 2 shows the functional groups of the evaluation board. Figure 2 Functional groups of the evaluation board 7ED020E12-FI-W2 The Evaluation board provides following main features: 2.2 - Rectifier, brake chopper and inverter integrated in one EasyPIM®2B module. - Functional isolation between high side and low side with coreless transformer technology. - Short circuit and over current protection. - Over temperature protection. - Over voltage protection. Pin assignment All the PWM signals and voltage supplies should be applied to the connectors X4 and X5. In the following table the pin assignment is given: Application Note 6 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module Table 1 Pin assignment of the connectors X4 and X5 Pin name Pin function X5-1 PWM_TOP_U X5-2 PWM_BOT_U X5-3 PWM_TOP_V X5-4 PWM_BOT_V X5-5 PWM_TOP_W X5-6 PWM_BOT_W X5-7 Enable X5-8 /Fault output X5-9 GND X4-1 Power supply 15V X4-2 GND 2.3 Mechanical dimension Figure 3 Mechanical dimension of 7ED020E12-FI-W2 Application Note 7 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module 3 Application note The evaluation board is powered by an external single power supply of +15 V at connector X4. A linear voltage regulator (IC7) provides from this source a second supply voltage of 5 V for the logic selector (IC5, IC6), timer (IC8), and comparators of IC1 to IC4. By default boot-strap circuits provide power to the highside IGBT drivers. The connectors X1, X2 and X3 offer the option of using three external power supplies for the high-side drivers instead of the boot-strap circuits. The EasyPIM®2B terminals EU, EV, EW and NB are shorted and connected through a shunt resistor R8 to the negative DC link voltage. Also GND for the drivers and peripheral electronic is connected to the negative DC link voltage. There is no galvanic isolation of common GND and negative DC link voltage. The logic selector (IC5, IC6) consists of two 74AC86 and sets the Active HIGH/LOW logic of the PWM inputs and the Enable signal for the drivers according to Table 1. The selection for either active HIGH or Active LOW logic is done by jumper J1. An external Enable signal at connector X5-7 is needed to turn on the drivers. In case the driver stages are not enabled, the timer output (IC8, Pin 3) has always HIGH state, which forces all drivers to shutdown through Q2 by a LOW signal at input /SD. The following table shows the truth table for the active high/low configuration: Table 2 Activ Low/High settings µController X5-1…X5-6=0 J1 Jumper on pin 1-2 (Active LOW) X5-7 (Enable) 0 OutL, OutH 1 X5-1…X5-6=0 Jumper on pin 1-2 (Active LOW) 1 0 X5-1…X5-6=0 Jumper on pin 2-3 (Active HIGH) 0 0 X5-1…X5-6=0 Jumper on pin 2-3 (Active HIGH) 1 0 X5-1…X5-6=1 Jumper on pin 1-2 (Active LOW) 0 0 X5-1…X5-6=1 Jumper on pin 1-2 (Active LOW) 1 0 X5-1…X5-6=1 Jumper on pin 2-3 (Active HIGH) 0 0 X5-1…X5-6=1 Jumper on pin 2-3 (Active HIGH) 1 1 Furthermore the electronic is constantly monitoring for short circuits, over currents and over temperature. In the event of a fault the timer input will be triggered (IC8, Pin 2) by a HIGH to LOW transition and sets the timer output (IC8, Pin 3) to HIGH. This HIGH signal will switch on Q1 and Q2. Q1 will signal the fault to Pin X5-8 (open-collector output) and Q2 will shutdown all drivers through the /SD input. The timer output will be reset to LOW defined by a delay time t = R20 • C23. In case the LOW signal at the trigger input remains the timer will wait until the trigger input receives a HIGH signal. Application Note 8 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module 3.1 Switching behavior The switching characterization with module FP35R12W2T4 was done using double pulse test. The following figures show the switching behavior at nominal current of 35A. The test was done at 25°C, 125°C and 150°C, 600V DC link voltage and 12Ω gate resistor conditions. Vge 5V/div Vge 5V/div Ic 10A/div Ic 10A/div Vce 200V/div Vce 200V/div Figure 4 Turn on (left) and turn off (right) with FP35R12W2T4 behavior @25°C Vge 5V/div Vge 5V/div Ic 10A/div Ic 10A/div Vce 200V/div Figure 5 Vce 200V/div Turn on (left) and turn off (right) with FP35R12W2T4 behavior @125°C Application Note 9 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module Vge 5V/div Figure 6 Vge 5V/div Ic 10A/div Ic 10A/div Vce 200V/div Vce 200V/div Turn on (left) and turn off (right) with FP35R12W2T4 behavior @150°C With the diagram the switching losses Eon and Eoff at 25°C, 125°C and 150°C can now be calculated. Table 3 Switching energy with FP35R12W2T4 Temperature Eon Eoff @25°C 2.3mJ 1.8mJ @125°C 3.1mJ 2.6mJ @150°C 3.4mJ 2.8mJ The switching losses are comparable with the values in listed in the datasheet. Furthermore there is no parasitic switching on to be observed in the turn on transient. 3.2 Over and short circuit current protection The shunt resistor voltage is filtered by an RC circuit (R19, C21) and forwarded to OP31 and OP4. OP3 is configured as non-inverting amplifier; OP4 is configured as inverting amplifier. Diode D12 and D13 are used to detect the maximum of both amplifier outputs. Therefore over current-protection is provided as well for positive DC-link current and for negative DC-link current. CP3 compares the voltage from amplifier OP3 to a reference voltage for over-current measurement, whereas CP4 detects short circuit-currents. The basic difference between CP3 and CP4 is the different reference voltage and time constant of the input RC-filters. In case the measured over- or short-circuit-current passes the threshold the associated comparator output turns LOW and triggers the timer input (IC8, Pin 2). A typical short circuit test was done: 1 The OP3 means the operation amplifier integrated in IC3. The same designation is used for the other CPs and OPs. Application Note 10 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module Vge 5V/div Vge 5V/div Vce 200V/div Vce 200V/div Ic 40A/div Figure 7 Ic 40A/div Short circuit test @25°C (left) and @125°C (right) To change the threshold of the over-current detection the reference voltage of CP3 has to be modified, i.e. increasing (decreasing) of R27 will increase (decrease) the threshold. To change the threshold time the RC circuit of R25 and C33 has to be modified, e.g. increasing (decreasing) of R25 will increase (decrease) the time. To change the threshold of the short-circuit-current detection the reference voltage of CP4 has to be modified, i.e. increasing (decreasing) of R29 will increase (decrease) the threshold. To change the threshold time the RC circuit of R26 and C34 has to be modified, e.g. increasing (decreasing) of R26 will increase (decrease) the time. 3.3 Brake chopper The DC link voltage is scaled down to a low voltage by resistors R36 to R44. The resulting voltage is compared by CP2 with a reference voltage. In case the DC link voltage is above the threshold, the output drives the low-side driver of IC4, which turns on the gate of the brake chopper. CP2 has a hysteresis defined by R47. To change the threshold for the brake chopper DC link voltage detection the reference voltage of CP2 has to be modified, i.e. increasing (decreasing) of R46 will increase (decrease) the threshold. The upper and lower threshold is defined by R47. 3.4 Over temperature protection Based on the built-in NTC in the module the bottom copper plane temperature will be monitored and in case of over temperature the driver will be shut down. The NTC together with R31 build a voltage divider, the voltage will be fed to the CP1 and compared with a reference voltage defined by the voltage divider consisting of R32 and R33. In case of over temperature the output of CP1 will be switched to low and triggers the timer input to switch down the drivers. Notice: This temperature measurement is not suitable for short circuit detection or short term overload and may be used to protect the module from long term overload conditions or malfunction of the cooling system. 3.5 /Fault output In case of short circuit, over current or over temperature the /Fault Pin (X5-8) will be switched to low to report an error to the microcontroller. After a definable delay time t=R20*C23 the driver will be switched on again if the fault condition does not exist anymore. So in case of fault condition, it is very important that the microcontroller is informed about the error and has been programmed to perform suitable actions. Application Note 11 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module 3.6 RMS current and DC link voltage limits The RMS current of the board is limited to be 10A. The maximum DC link voltage is limited to be 800V. With a brake resistor connected, the brake chopper will limit the DC link voltage according to the set point as described in section 3.3. 3.7 Indication of the surge current at turning on of the board The board has built-in thermistors to prevent the rectifier diodes from the surge current at plugging in. Once the board is plugged into the power supply with the thermistors being still cold, the input current will be limited. After a while, the thermistors will get hot and the resistance decrease to provide a low impedance power supply for the board. Notice: After a while of operation, the thermistors are getting hot and have a low resistance value. If the board is disconnected from the power supply and is connected again immediately, it is possible to damage the rectifier diodes with large surge current. 3.8 Cooling condition The board is provided without heat sink. However, a heat sink is necessary for the proper operation of the board. For dimension of heat sink, it is recommended to refer to the software IPOSIM from Infineon. 4 Schematic, Layout and Bill of Material In the following sections the schematic, layout and bill of material of 7ED020E12-FI-W2 will be provided. 4.1 Schematic Application Note 12 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module Figure 8 Input stage Figure 9 Driver stage Figure 10 Power stage Application Note 13 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module Figure 11 Fault timer Figure 12 OV OC SC and OT protection circuit Application Note 14 V1.0, 2007-04 AN2007-03 Evaluation Board for EasyPIM®2B module 4.2 Layout Figure 13 Layout of Top layer Figure 14 Layout of bottom layer Application Note 15 V1.0, 2007-04 AP99007 Driver Board for Easy2B module Page 4.3 Bill of material Type Jumper Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor Capacitor amount 1 1 5 3 1 3 1 1 value/type package size 1µ 1n 2.2µ 9POL2.54 10n 33n 47µ 1206 1206 Tantalum, size D 9POL2.54 1206 1206 CPOL-EUE2,5-6E name part J1 C33 C21, C27, C28, C34, C36 C6, C12, C18 X5 C29, C31, C35 C26 C23 C4, C10, C16, C24, C25, C30, C32, C37, C38 Capacitor 9 100n C-EUC1206K Capacitor 4 4u7 C-EUC1206K Capacitor Connector 11 330p 4 2POL2.54 Connector 10 Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor 3 3 3 1 1 1 1 3 1 1 10R 2R2 2k 3.3k 5.1k 8.2k 9.1k 10k 13k 15k Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor Resistor 7 3 1 1 1 1 1 1 1 1 15k 15k 18k 18m 22k 27k 33R 33k 56k 82k Resistor Resistor Application Note 10 100R 1 100k C-EUC1206K 2POL2.54 Tab terminals, type Vogt 3866G.68 (F061.080) R1206 from TT Electronics, serie: PWC. NTC_EPCOS 1206 1206 1206 1206 1206 1206 1206 SOMC1601 1206 1206 1206 5020 1206 1206 1206 1206 1206 1206 1206 1206 16 C5, C11, C17, C22 C1, C2, C3, C7, C8, C9, C13, C14, C15, C19, C20 X1, X2, X3, X4 B, L1, L2, L3, N, P, P1, U, V, W R64, R65, R66 R50, R51, R52 R16, R34, R48 R44 R18 R46 R21 R22, R25, R49 R27 RN1 R9, R10, R11, R12, R13, R14, R15 R24, R29, R32 R30 R8 R45 R28 R57 R33 R35 R20 R53, R54, R55, R56, R58, R59, R60, R61, R62, R63 R23 V1.0, 2007-04 AP99007 Driver Board for Easy2B module Page Resistor Resistor Resistor 1 150k 2 470R 1 560k 1206 1206 1206 Resistor Resistor Semiconductor Semiconductor Semiconductor Semiconductor 8 1 4 2 1 5 680k 820R 2ED020I12-F 74AC86D 78L05 BCR533 1206 1206 PG-DSO-18-2 14-SOIC SO-8 SOT23 Semiconductor Semiconductor Semiconductor Semiconductor Box 7 1 2 3 1 BZV55C16 LMC555 LS103A STTA112U D-SOD-80 SO-8 D-SOD-80 SMB Gate resistor list Part type FP25R12W2T4 FP35R12W2T4 FP50R06W2E3 5 Recommended gate resistor 20R 12R 8R2 Package 1206 1206 1206 R47 R19, R31 R17 R36, R37, R38, R39, R40, R41, R42, R43 R26 IC1, IC2, IC3, IC4 IC5, IC6 IC7 Q1, Q2, Q3, Q4, Q5 D4, D5, D6, D7, D8, D9, D10 IC8 D12, D13 D1, D2, D3 Name part R1, R2, R3, R4, R5, R6, R7 R1, R2, R3, R4, R5, R6, R7 R1, R2, R3, R4, R5, R6, R7 How to order the evaluation board Every Evaluation Driver Board has its own SAP number and can be ordered via your Infineon Sales Partner. Information can also be found at the Infineons Web Page: www.infineon.com Application Note 17 V1.0, 2007-04 http://www.infineon.com Published by Infineon Technologies AG