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 Page 4 of 20 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 Page 5 of 20 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 Page 6 of 20 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 Page 7 of 20 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 Page 8 of 20 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 Page 12 of 20 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 Page 13 of 20 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 ja 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 Page 14 of 20 5 Schematics Figure 12: Driver Circuit Phase U Figure 13: Driver Circuit Phase V EVA_P58x for PIM / CIB Modules Page 15 of 20 Figure 14: Driver Circuit Phase W Figure 15: Brake circuit and voltage divider EVA_P58x for PIM / CIB Modules Page 16 of 20 Figure 16: Connectors Figure 17: P58x Power Module EVA_P58x for PIM / CIB Modules Page 17 of 20 6 Layout Figure 18: Assembly drawing EVA_P58x for PIM / CIB Modules Page 18 of 20 Figure 19: TOP layer Figure 20: BOTTOM layer EVA_P58x for PIM / CIB Modules Page 19 of 20 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 Page 20 of 20