Evaluation board description for flowPIM 1 power modules

Reference Design
Evaluation Board for
flowPIM 1 Power Modules
EVA_P58x for PIM / CIB Modules
Reference Design no.:
RD_2011-01_001-v04
Table of Contents
1
In tr o d uc t i o n ............................................................................................. 4
2
Fe at ur es of dr i v er b o a r d ............................................................................ 5
2. 1
Ma i n f ea tu r es ........................................................................................... 5
2. 2
E lec tr ic al par am et er s ................................................................................ 6
2. 3
P in as s i g nm ents ....................................................................................... 7
2. 4
Mec h an ic a l d im ens i on s ............................................................................. 7
3
Des c r i pt i o n of e l ec tr ic a l par ts .................................................................... 8
3. 1
P o wer m o du l e .......................................................................................... 8
3. 2
Re q ui r e d p o wer s u p pl y .............................................................................. 9
3. 3
In p ut / o ut p ut s ig n als ................................................................................ 9
3. 4
Fa ul t o ut p ut a n d S D i n pu t ......................................................................... 9
3. 5
G at e r es is tor ........................................................................................... 12
3. 6
S wi tc h i n g f r e q ue nc y ................................................................................. 13
4
Def in i ti o n of la ye r s .................................................................................. 14
5
Sc hem at ic s ............................................................................................. 15
6
La yo u t .................................................................................................... 18
7
B i ll of m ater i a l ......................................................................................... 20
Disclaimer: The information in this document is given as an indication for the purpose of implementation only and
shall not be regarded as any description or warranty of a certain functionality, condition or quality. The statements
contained herein, including any recommendation, suggestion or methodology, are to be verified by the user before
implementation, as operating conditions and environmental factors may vary. It shall be the sole responsibility of the
recipient of this document to verify any function described herein in the given practical application. Vincotech GmbH
hereby disclaims any and all warranties and liabilities of any kind (including without limitation warranties of noninfringement of intellectual property rights of any third party) with respect to any and all information given in this
document.
Revision history:
Date
Jan. 2011
Mar. 2011
Sep. 2011
Jul. 2012
Revision
Level
1
2
3
4
Description
First release
Change of pictures
Corrected pin assignment for J6
Updated and added several diagrams
EVA_P58x for PIM / CIB Modules
Page
number(s)
20
20
20
20
Page 3 of 20
1
Introduction
This application note describes the Evaluation Driver Board for the module family P58x or in other words
rd
the flowPIM 1 3 generation. This board provides a plug and play solution identifying the switching
behavior and efficiency of this module family.
The following picture shows the driver board without an IGBT module. This board can be used for the
rd
complete range of flowPIM 1 3 generation modules by simply changing the components that are
highlighted in table 4. The board will be delivered without these components and also without the power
module. The components have to be added according to the selected module to each board and the
module have to be ordered separately.
Ordering Number: EVA_P58x
MOTOR OUTPUT
LINE INPUT
BOOT STRAP
DIODES
IGBT DRIVER
SHUNTS
CONTROL
CONNECTOR
DC LINK
CAPACITOR
DC POWER CONNECTOR
(+5V; +15V)
RECTIFIER OUT
DC LINK IN
BRAKE
GATE RESISTOR
VOLTAGE LIMITER RESISTOR
CURRENT LIMITER RESISTOR
TEMPERATURE LIMITER RESISTOR
Figure 1: Evaluation driver board without a module
EVA_P58x for PIM / CIB Modules
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2
Features of driver board
The next chapter describes the main features, basic electrical parameters as well as pin assignments
and mechanical dimensions.
2.1
Main features

Two channel drivers for each leg

Supply for upper IGBT drivers through bootstrap circuit

Ground potential of drivers related to DC-

Under voltage lockout

3.3V and 5 V TTL compatible inputs

Non-inverting inputs

Dedicated SD shutdown input (active high)

One FAULT_NEG fault output signal (active low)

Over voltage, over-current and over-temperature limitation by onboard comparator

DCV DC-link voltage, DCI DC-link current amplified analog outputs

Heatsink temperature sense with thermistor

+15 V power supply for the drivers

+5 V power for amplifier and references

Gate drive currents of +1 A / –2 A

Suitable for up to 600 V / 50 A and 1200 V / 35 A modules

PCB designed to fulfill the requirements of IEC61800-5-1, pollution degree 2, over voltage
category III
EVA_P58x for PIM / CIB Modules
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2.2
Electrical parameters
The electrical characteristics involve the guaranteed value spread for the supply voltages, load and
junction temperature given below. Typical values represent the median values, which are related to
production processes. Unless otherwise noted all voltages are given with respect to ground (GND). VSL
= 15 V, VSH – GNDH = 14 V (15V - (bootstrap diode voltage and low-side IGBT forward
drop) = 14 V).
CL = 1 nF, Ta = 25 °C. Positive currents are assumed to be flowing into pins.
UCE – max for 600 V modules
UCE – max for 1200 V modules
IC – RMS current through PCB
UDC – supply voltage for drivers
UCC – supply voltage for logic and analog
Voltage for logic inputs
UInH, UInL, SD
min.
typ.
15
5
max.
600
1200
30
16
5.3
Unit
V
V
A
V
V
14
4.9
0
5
5.3
V
Remarks
@ Th = 80 °C
reference to shunt
DCI current analog output gain
4.34
V/V
DCV voltage analog output gain 1200/600
Over Current protection
Over Voltage protection 1200/600
Over Temperature protection
3/5
1/(2*shunt)
735/440
80
V/480V
A
V
°C
voltage
1) set by shunt
1) set by R14
1) set by PWM
fsw – switching frequency
2
8
16
kHz
controller
Rth(j-a) – driver IC
90
K/W
TVJmax – Junction temperature
-40
150
°C
TST – Storage temperature
-40
85
°C
1)
Refer to the next table
For additional information refer to the datasheet of 2ED020I12-FI from Infineon
Table 1: Electric parameters
The following table shows the different modules available in the P58x series. Here information about the
recommended switching frequency and the recommended passive components are mentioned.
Module
Current [A]
Voltage [V]
Frequency*[kHz]
Shunt Rsw4 …
Rsw6 [Ω]
R14 [kΩ]
Gate resistors
[Ω]
C14 [µF]
*: optimum
P580
-A41
35
1200
4
P589
P580
P589
-A31
25
1200
8
P588
-A41
15
1200
4
P588
P585
P586
35
1200
4
P589
-A41
25
1200
4
25
1200
4
15
1200
4
30
600
8
50
600
8
0.015
0.015
0.015
0.015
0.015
0.03
0.03
0.015
0.01
2
2
2
2
2
2
2
4
4
16
32
16
32
32
32
32
16
16
0.47
0.47
0.47
0.47
0.47
0.47
0.47
1
1
Table 2: Members of P58x family
Note: Other modules with the same pinning can be driven as well as long as the maximum RMS current
is not exceeded.
EVA_P58x for PIM / CIB Modules
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2.3
Pin assignments
The driver board has connectors to provide the power to the PCB and to support signals to e.g. the
driver circuit.
J5
1
+15 V
2
+5 Vref
3
GND
4
BrG
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
*: active high
J6
TH1
TH2(GND)
BrG
+5 V
SD*
+15 V
FAULT
DCV
WL
DCI
WH
NC
VL
GND
VH
GND
UL
GND
UH
GND
Table 3: Pin assignment for connector J5 and J6
2.4
Mechanical dimensions
Mechanical dimensions for width, length and height (without module): 111 mm x 81 mm x 23 mm
81 mm
111 mm
Figure 2: PCB of Evaluation Driver Board
EVA_P58x for PIM / CIB Modules
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3
Description of electrical parts
This chapter describes the different electrical parts like the input signals, output signals and driver circuit
for better understanding of how the board works. Also shown in this chapter are some hints to adjust
switching speed and performance of the used IGBT module.
3.1
Power module
In this module family a 3~ rectifier is used to convert the voltage from AC to DC. P58x modules are
available with and without a brake chopper. Six IGBTs with freewheeling diodes are implemented for the
conversion from DC to AC. The IGBTs and the freewheeling diodes have the same current rating.
Therefore the modules can be used for 100 % braking operation.
Figure 3: Topology of P58x module family
For temperature measurement a NTC is equipped. Note that this NTC has only a functional isolation.
EVA_P58x for PIM / CIB Modules
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3.2
Required power supply
To ensure a correct operation of the evaluation board a 15V power supply for the gate drivers and 5V for
the logic and analog signals have to be connected.
3.3
Input / output signals
The switching of the IGBT inverter needs to be controlled by 6 PWM channel and the PWM voltage level
is 3.3 - 5.3 V.
For measuring the DC link voltage and current DCV, DCI analog output signals are provided. These are
generated by universal operational amplifiers of the gate driver ICs. The TH1 thermistor output is
available without amplification to measure the heatsink temperature from the power module.
The reference point TH2 of the thermistor needs to be connected to GND in order to activate the overtemperature protection on the driver board.
3.4
Fault output and SD input
All fault outputs are connected together to get one collective fault. The fault output is activated for overvoltage or over-current on the DC link or over-temperature on the heatsink.
The fault signal is not latched, which means that the fault signal is active only for the duration of overload
condition.
By nature, the fault caused by the over-current signal can be of short duration so the signal must be
latched or the software must react within the allowed t sc short-circuit time of the IGBTs.
A SD shutdown input is provided to keep all drive signals off for fast reaction.
The entire driver ICs contain one amplifier and one comparator (Figure 4, Figure 4, Figure 6). These are
responsible for the threshold voltage for over current, over voltage and over temperature. If one of the
three paths exceeds the threshold voltage the SD will be activated, as every comparator’s output is in
connection. The output of comparators needs to be inverted.
The reference voltages of the comparators are set to 490 mV according to the following equation:
For additional information please refer to the driver’s datasheet of the 2ED020I12-F from Infineon.
EVA_P58x for PIM / CIB Modules
Page 9 of 20
Figure 4: Input driver circuit for current measurement & limitation
The operation amplifier of the driver IC is used to handle the measured current in the emitter shunts
RsW4 to RsW6.
Resistor R39 sets the threshold voltage for the over current detection. The next equation shows how the
current detection can be changed:
If the resistor R39 is reduced it will result in an increase of current limitation.
For current measurement the VDCI voltage is given by the following equation:
Figure 5: Over current detection and current measuring waveforms
EVA_P58x for PIM / CIB Modules
Page 10 of 20
The driver IC U5 handles the measured DC-Link voltage (DCV) through the operation amplifier. The over
voltage threshold can be adjusted with R38. The next equation shows how the current detection can be
changed:
The voltage limit can be decreased with increasing R38. For 600 V modules R14 has to be 4 kΩ, and for
1200 V modules R14 has to be 2 kΩ.
Figure 6: Input driver circuit for voltage limit and measurement for 1200 V modules
For DC+ voltage (high voltage DC link) measurement the VDCV voltage is given by the following equation:
Figure 7: Over voltage detection and voltage measuring waveforms
EVA_P58x for PIM / CIB Modules
Page 11 of 20
The driver IC U4 handles the resistance of the build in NTC through the operation amplifier.
Figure 8: Input driver circuit for temperature limit
Working of the temperature limit is the same as previous shown in. Here resistor R37 can be changed to
adjust the temperature trip.
3.5
Gate resistor
The P58x family consists of several power ratings. Therefore the gate resistor has to be adjusted to
guarantee best switching performance like shown in Table 2. On the other hand the switching speed and
there the gate resistor as well influence the EMI behavior.
Figure 9: Gate resistors. Here bottom IGBT phase W with 16 Ω
EVA_P58x for PIM / CIB Modules
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The driver board has two gate resistors for each IGBT and a diode as can be seen in Figure 9. In this
configuration the turn-on and the turn-off can be adjusted independently. For the switch-on of the IGBT
the bottom resistor is active only. If the IGBT gets the turn-off signal, the upper path is active. In case
that the IGBT gets an undefined signal from the driver, the 15 kΩ resistor between gate and emitter
short-circuits.
The gate resistors are: R18, R19; R20, R21; R22, R23; R24, R25; R26, R27; R28, R29
Table 2 shows which value of gate resistor should be implemented.
3.6
Switching frequency
The switching frequency is limited by the maximum heat dissipation or in other words the maximum
junction temperature of the driver IC.
With the following equation the needed power for driving an IGBT at a given frequency can be
calculated.
P  f sw  U GE  Qge
f sw stands for the applied switching frequency for the switch. The difference of the turn-on voltage and
turn-off voltage is expressed with U GE and the gate charge
Qge is given in the module datasheet.
The gate charge voltage diagram is given in the modules datasheet.
Example: Gate Charge Curve
20
15
Gate Voltage [V]
10
5
0
-5
-10
-15
0
0.2
0.4
0.6
0.8
1
Gate Charge Standardized
Figure 10: Nominated Gate charge curve
EVA_P58x for PIM / CIB Modules
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The evaluation driver board works with a gate emitter voltage U GE of 15 V.
With a given power loss P the rise of the junction temperature of the driver can be calculated:
T ja   P  Rth j a 
In this case
Rth  j a  is the thermal resistance given in the datasheet of the driver IC.
Finally the ambient temperature and the maximum operation temperature of the PCB have to be defined.
The used PCB material in case of the driver board is FR4, which allows an operation temperature of
105_°C.
4
Definition of layers
The driver board is based on a 2-Layer PCB. The used material is FR4. Figure 11 depicts a cross
section for the layer thickness and for pre-packs.
1
1
Copper:
1: 105 µm
2: 105 µm
2
Isolation:
1-2: 2 mm
2
Figure 11: Copper thicknesses and isolation for layers
EVA_P58x for PIM / CIB Modules
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5
Schematics
Figure 12: Driver Circuit Phase U
Figure 13: Driver Circuit Phase V
EVA_P58x for PIM / CIB Modules
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Figure 14: Driver Circuit Phase W
Figure 15: Brake circuit and voltage divider
EVA_P58x for PIM / CIB Modules
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Figure 16: Connectors
Figure 17: P58x Power Module
EVA_P58x for PIM / CIB Modules
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6
Layout
Figure 18: Assembly drawing
EVA_P58x for PIM / CIB Modules
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Figure 19: TOP layer
Figure 20: BOTTOM layer
EVA_P58x for PIM / CIB Modules
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7
Bill of material
Qty
Value
Device
1n
Designator
Part name(s)
2n2
10n
10u / 25V
47u
0603
MKP1840
0603
0603
3528
7343
C91
C14
C16
C3
C11, C12, C13
C15
C1, C2, C4, C5, C6,
C7, C8, C9, C10,
C70, C90
J6
J5
D10, D11, D12, D13,
D14, D15
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
Capacitor
1
1
1
1
3
1
Capacitor
11
100n
0603
Connector
Connector
1
1
20PIN
CON4
IDC20
SIP4
Diode
6
BAS385
MICROMELF
Diode
3
BYG21M
IC
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
Resistor
3
3
1
2
4
1
1
1
1
2
2
1
1
1
DO-214ACHV
2ED020I12 P-DSO-18
4527
0603
0603
1k
0603
3k
0603
0603
20k
0603
51k
0603
2k7
0603
10k
0603
3k9
0603
2k
0603
15k
0805
Resistor
7
15k
0603
Resistor
1
18k
0603
R49
Resistor
1
11k
0603
Resistor
6
0805
Resistor
6
0805
Resistor
1
33
0805
Resistor
4
120k
1210
Resistor
Resistor
Transistor
Transistor
Transistor
Module
1
1
1
1
1
1
200
330
BC847
BCX53
BCX56
P58x
0603
0603
SOT-23
SOT-89
SOT-89
flow1
R48
R19, R20, R23, R25,
R26, R29
R18, R21, R22, R24,
R27, R28
R90
R44, R45, R441,
R451
R72
R46
Q1
Q91
Q90
U7
Preferred
supplier
DC-Link; refer to Table 2
Boot-Strap
Capacitor
Switch-off driver path
D7, D8, D9
U4, U5, U6
RsW4, RsW5, RsW6
R37
R38, R39
R40, R41, R42, R43
R47
R14
R13
R71
R16, R17
R70, R73
R50
R15
R0
R30, R31, R32, R33,
R34, R35
Comment
Boot-Strap Diode
Infineon
Driver for IGBT modules
refer to Table 2
Refer to Chapter 3.4
Refer to Chapter 3.4
refer to Table 2
Gate-emitter pull down
Rg_off; refer to Table 2
Rg_on; refer to Table 2
Voltage divider
Vincotech
PNP Bipolar Transistor
NPN Bipolar Transistor
PIM module; refer to Table 2
Table 4: Bill of material
Highlighted positions have to be assembled
EVA_P58x for PIM / CIB Modules
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