Reference Design Evaluation Board for flowIPM 1B Power Modules EVA P95x for flowIPM 1B Reference Design no.: RD_2011-03_002-v02 Table of Contents 1 In tr o d uc t i o n .................................................. E rr or ! Boo km a rk not def ine d. 2 Fe at ur es of dr i v er b o a r d ................................. E rr or ! Boo km a rk not def ine d. 2. 1 Ma i n f ea tu r es ................................................ E rr or ! Boo km a rk not def ine d. 2. 2 E lec tr ic al par a m et er s ..................................... E rr or ! Boo km a rk not def ine d. 2. 3 P in as s i g nm ents ............................................ E rr or ! Boo km a rk not def ine d. 2. 4 Mec h an ic a l d im ens i on s .................................. E rr or ! Boo km a rk not def ine d. 3 Des c r i pt i o n of e l ec tr ic a l par ts ......................... E rr or ! Boo km a rk not def ine d. 3. 1 P o wer m o du l e ............................................... E rr or ! Boo km a rk not def ine d. 3. 2 Re q ui r e d p o wer s u p pl y ................................... E rr or ! Boo km a rk not def ine d. 3. 3 In p ut / o ut p ut s ig n als ..................................... E rr or ! Boo km a rk not def ine d. 3. 4 Fa ul t o ut p ut a n d S D i n pu t .............................. E rr or ! Boo km a rk not def ine d. 3. 5 G at e r es is tor ................................................. E rr or ! Boo km a rk not def ine d. 3. 6 S wi tc h i n g f r e q ue nc y ....................................... E rr or ! Boo km a rk not def ine d. 4 Def in i ti o n of la ye r s ........................................ E rr or ! Boo km a rk not def ine d. 5 Sc hem at ic s ................................................... E rr or ! Boo km a rk not def ine d. 6 La yo u t .......................................................... E rr or ! Boo km a rk not def ine d. 7 B i ll of m ater i a l ............................................... E rr or ! Boo k m a rk not def ine d. 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 Mar. 2011 Jul. 2012 Revision Level 1 2 EVA P95x for flowIPM 1B Description First release Updated schematics, BOM and new layout Page number(s) 22 22 Page 3 of 22 1 Introduction In this application note the Evaluation Board for the module P95x or in other words the flowIPM 1B is described. This board gives a plug and play solution to get familiar with the switching behavior and efficiency of the mentioned module. The following picture shows the driver board. This board can be used for the complete range of flowIPM 1B 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_P95x DC LINK CAPACITOR MOTOR OUT PFC CONTROLLER EARTH MODULE ANALOG MEASUREMENT CONTROL PFC CHOKE AC out AC / DC ACin + EMC FUSE Figure 1: Evaluation board for P95x modules (sample picture) EVA P95x for flowIPM 1B Page 4 of 22 2 Features of the board The next chapter describes the main features, basic electrical parameters as well as pin assignments and mechanical dimensions. 2.1 Main features P95x power module featuring rectifier, PFC, six-pack with driver, and current sensing shunts Complete 1 kW PFC circuit with PFC controller (switching frequency settable by resistor) 110 VAC – 230 VAC single phase input with 2 stage EMC filter, fuse and NTC inrush protection 380 VDC link (settable by resistor) phase 230 VAC motor output V TTL compatible inverting (active low) PWM inputs for the six-pack Dedicated Enable input (active high) Fault output signal (open collector) AC/DC converter for powering the PFC controller, circuit for measurement and the gate drivers in the module PCB is designed to fulfill the requirements of IEC61800-5-1, pollution degree 2, overvoltage category III 2.2 Electrical parameters max. 250 5 450 Unit VAC Arms VDC AC output voltage 240 VAC AC output current Module_Fault_N output UInH, Voltage for logic Inputs UInL Input current for PWM S_PFC S_INV DC2+_M Analog output DC1+_M 3.5 8 2.4 1.1 200 3 3 Arms mA AC input voltage AC input current DC link voltage Reference voltage min. 90 typ. 230 400 1.7 0.7 2.1 0.9 0 0 U_REF U_REF U_REF 1.6 106 133 Thmax – Power Module TOP – Operation ambient temperature -40 TST – Storage temperature -40 Table 1: Electric parameters EVA P95x for flowIPM 1B Open collector Inverse TTL 0.22 V/A 0.25 V/A @400 VDC V 1.83 2.7 @400 VDC link, 3~, SPWM µA 2.26 NTC2 fsw PFC – switching frequency V Remarks 47-63 Hz @324 Vdcpeak @Th = 25 °C 161 kHz 100 85 85 °C °C °C Shunt current measurement @R4xR_frek= 33 kΩ Page 5 of 22 2.3 Pin assignments Connector Pin name Direction Description Symbol Pin F1 L L Power I 1~ power input N N Power I Null potential input Earth Earth Power I/O Safety earth U U Power O 3~ output to motor drive V V Power O 3~ output to motor drive W W Power O 3~ output to motor drive Earth Earth Power I/O Safety earth 1 GND Power O Power for measure logic 2 S_PFC Analog O Analog signal from PFC shunt measured 3 NC Not connected 4 S_INV Analog O 5 NC Not connected 6 DC2+_M Analog O Analog signal from DC2 link 7 DC1+_M Analog O Analog signal from rectifier output 8 NTC2 Analog O Analog signal from NTC 9 NC Not connected 10 15V Power I Power for measure logic 1 GND Power O Power for control logic 2 HIN3_N TTL I control signal, active low 3 LIN3_N TTL I control signal, active low 4 HIN2_N TTL I control signal, active low 4 LIN2_N TTL I control signal, active low 6 HIN1_N TTL I control signal, active low 7 LIN1_N TTL I control signal, active low 8, 9 NC Not connected 10 Module_Fault_N O 11-17 NC Not connected 18 Module_Enable TTL I 19 NC Not connected 20 15V Power I J1 AOUT Control Analog signal from six pack shunt measured Open collector fault signal with internal pull up resistor, active low Module shut down signal Power for control logic Table 2: Pin description of connectors EVA P95x for flowIPM 1B Page 6 of 22 2.4 Mechanical dimensions Mechanical dimensions for width and length: 124 mm x 123 mm Figure 2: PCB of Evaluation Driver Board 3 Description of electrical parts This chapter describes the different electrical parts like the input signals, output signals and driver circuit for better understanding how the board works. In this module a 1~ rectifier is used to convert the voltage from AC to DC. The PFC MOSFET with gate driver makes a Power Factor Correction, so the UDC1+ voltage and the rectified current have got same phase shift. Six IGBTs with free-wheeling diodes are implemented for the conversion from DC to AC with variable frequency. There is no braking chopper on the board; therefore the modules can not be used for braking operation. The power requirement of P95x kit is a very basic, 1~ AC 110 V – 230 V. For the internal power supply for drivers and measure circuit a compact AC/DC converter is implemented. Please refer to the P95x datasheet for more information about the power module: EVA P95x for flowIPM 1B Page 7 of 22 http://www.vincotech.com/products/by-topologies.html > IPM For measurement of the heatsink temperature an NTC is equipped. Figure 3: Topology of P95x module family 3.1 Input filter and rectification The input AC voltage rectification is implemented by bridge. The single phase AC input is connected to F1 which includes one stage EMC filter and the second stage (I1, C4) is added on board. An NTC is limiting the inrush current at start up. The fuse protects the whole circuit. Figure 4: Input filter and rectification The rectified voltage on pin 19 and pin 21 of the module is DC1 link. These powers up to the PFC circuit which is described in the next chapter. EVA P95x for flowIPM 1B Page 8 of 22 3.2 PFC 1 kW PFC circuit is included in the board with settable switching frequency and settable DC2 link voltage and with C2 capacitor (470 µF/450 VAC). The PFC MOSFET, PFC diode, gate driver and shunt resistor have been integrated in the module. The value of the PFC inductor L1 is 0.7 mH. D1 and D2 are protection diodes for the PFC shunt and PFC diode. Figure 5: PFC power circuit EVA P95x for flowIPM 1B Page 9 of 22 The switching signals for the integrated MosFet are generated by the ICE2PCS01 PFC controller. This is powered with an AC/DC converter supplying +15 V. Two resistors connected to pin 4 of the PFC controller adjust the switching frequency. This is set by R4 and R_frek to 130 kHz. Changing R_frek change the switching frequency. R frec _ set R4 R _ frek R4 R _ frek The datasheet of the ICE2PCS01 shows a diagram with the dependency of Rfrec_set and the switching frequency. The voltage of DC2+ can be modified with the resistor R_dc. Figure 6: PFC controller circuit The default voltage is approx. 400 VDC. This is the maximum suggested DC-Link voltage. The following equation shows how to adjust the voltage of the DC-Bus. The internal reference voltage of the PFC controller is 3 V. U DC 2 R8 R _ dc 3V R 2 R6 R7 R8 R _ dc R8 R _ dc R8 R _ dc There has been a 90 mΩ PFC shunt resistor integrated in module. By this shunt the PFC current can be measured. The kit contains dual differential amplifier. One amplifier is used to measure the current through the PFC shunt and the other amplifier is used to measure the DC-Link current which will be explained more in detail in the next chapter. An additional voltage U_REF can be applied to Pin 9 of the AOUT connector to shift the amplified signals of the PFC shunt measurement and the inverter shunt measurement to a level that is suitable for the used microcontroller. This can be e.g. 2.5 V or 3.3 V. EVA P95x for flowIPM 1B Page 10 of 22 Pin 2 of AOUT connector has U_REF potential when no current is driven through the PFC shunt. If the PFC stage works the S_PFC output signal change according to the current through the shunt. Refer to the following figure. Figure 7: Picture of differential amplifier at PFC shunt resistor Check the PFC controller under this link: http://www.infineon.com/cms/en/product/findProductTypeByName.html?q=ice2pcs01 3.3 Inverter part and shunt measurement The inverter switches, contained in the module gets the drive signals from the TTL level PWM input signals. Level shifters and high side bootstrap driver are also included in the module. For the measurement of the motor current a DC link shunt with a value of 100 mΩ is implemented in the module in the common emitter of low side IGBTs. InvS+ and InvS- are connected direct to the inverter shunt and provide a signal through the second differential amplifier to the AOUT connector. Like for the PFC shunt measurement the output signal is shifted with the U_REF voltage. If the motor is not in operation U_REF is forwarded to pin 4. If the motor is driven, the potential of pin 4 will change according to the current flow through the shunt. Figure 8: Picture of differential amplifier at six pack shunt resistor EVA P95x for flowIPM 1B Page 11 of 22 3.4 Voltage measurements The kit contains two voltage dividers. Through those the voltage after the rectification UDC1+ and the voltage after the PFC stage UDC2+ can be measured. The output of voltage dividers is 1.83 Vpeak / 324 Vpeak for the UDC1+_M and 2.20 V / 400V DC in case of UDC2+_M. The voltages are provided to the connector AOUT. The following equations show how to calculate: U DC1 _ M U DC1 R58 R46 R51 R53 R58 U DC 2 _ M U DC 2 R57 R45 R50 R52 R57 Figure 9: Picture of voltage divider It is recommended only to change R57 or R58. EVA P95x for flowIPM 1B Page 12 of 22 3.5 Temperature measurement The internal NTC for temperature measurement can be monitored via the AOUT connector. For calculating heatsink temperature the following circuit can be used, and the NTC characteristics can be read from the module datasheet: Figure 10: NTC measurement circuit The thermistor has a resistance of 22 kΩ at 25 °C and a B(25/50)-value of 3950 K. The relation between resistance and temperature of the NTC is expressed as: 1 1 B25/ 50 T2 298,15K RNTC R25. Where T2 is the measured NTC temperature. 4 Operation The module can be activated via an active high signal on the pin 3 of the control connector. By default the module is disabled. Before the module can handle the PWM signals from the microcontroller if is necessary to wait at least 800 ns after the enable signal is applied. The following startup sequence should be applied: MODUL_ENABLE signal go LOW wait for at least 800 ns start the PWM MODULE_ENABLE signal go HIGH Fault signal is generated in case of short circuit on the output. In this case set the MODULE_ENABLE signal to disable within 5 µs time, and it must be kept in this state for at least one second. The number of allowed short circuits is limited to 1000. The recommended switching frequency is 16 kHz. Check the sixpack driver IC under this link: http://www.infineon.com/cms/en/product/findProductTypeByName.html?q=6ED003L06-F+ EVA P95x for flowIPM 1B Page 13 of 22 5 Definition of layers The driver board is based on a 2-Layer PCB. The used material is FR4. Figure 11 depicts a cross section of the layer thickness and for pre-packs. 1 1 Copper: 1: 35 µm 2: 35 µm 2 Isolation: 1-2: 1.6 mm 2 Figure 11: Copper thicknesses and isolation for layers 6 Layout Figure 12: Assembly drawing TOP EVA P95x for flowIPM 1B Page 14 of 22 Figure 13: Assembly drawing BOTTOM EVA P95x for flowIPM 1B Page 15 of 22 Figure 14: TOP layer EVA P95x for flowIPM 1B Page 16 of 22 Figure 15: BOTTOM layer EVA P95x for flowIPM 1B Page 17 of 22 7 Schematics Figure 16: Input circuit Figure 17: PFC circuit Figure 18: PFC controller circuit EVA P95x for flowIPM 1B Page 18 of 22 Figure 19: PFC shunt measurement Figure 20: Inverter shunt measurement EVA P95x for flowIPM 1B Page 19 of 22 Figure 21: Temperature and voltage measurement Figure 22: Connectors EVA P95x for flowIPM 1B Page 20 of 22 Figure 23: Power module Figure 24: AC/DC power supply Figure 25: Voltage reference adjustment EVA P95x for flowIPM 1B Page 21 of 22 8 BOM Ordering code 5V, 15V AC/DC1 AOUT C1, C7 C2 C3 C4, C5, C8, C11, C12, C13, C14, C15, C16, C17, C18, C19, C20, C24, C25 C6 C9 C10, C22, C23 C21 CONTROL D1, D2 F1 Fuse F1 Holder for fuse F1 Cover for fuse holder I1 J1 L1 ME NTC R1 R2 R3 R4 R5 R6 R7 R8 R9, R15, R16, R23 R10, R13 R11, R14 for 10 A modules R11, R14 for 4 A modules R12, R29, R30 R17, R21 R18, R22 for 10 A modules R18, R22 for 4 A modules R19, R20, R24, R25 R26 R27, R28 R31 R32 R_dc R_frek U1 U2, U4 U3 VR1 M1 Manufacture Liteon: LTST-C170KGKT TMLM 04115 TKP: SCMI10 Vishay: BFC233621474 NACZ470M35V6.3X6.3TRF Epcos: B37941-K5102-K060 TDK: C2012X7RH102K Kemet: C0805C104K3RAC Murata: GRM21BR71E104KA01K Epcos: B43508-A5567-M067 AVX: 08053C105KAT2A Kemet: C0805C105K3RAC 05007-BP471BKZCT Kemet: C0805C103K5RAC Murata: GRM216R71H103KA01D TKP: SCMI20 Vishay: P600M-E3 Various Various Various Epcos: B82725S2602N041 AK100/4DS-10.0V Epcos: B82615B2602M001 Delta 06ME2 Epcos: B57237S0509M051 Vishay: CRCW08053R30FKTA Vishay: CRCW1206300KFKTA Vishay: CRCW0805220RFKTA Walsin: WR08X1002FTL Vishay: CRCW080582K0FKTA Vishay: CRCW080535K0FKTA Vishay: CRCW1206270KFKTA Vishay: CRCW1206200KFKTA Walsin: WR08X4702FTL CRCW08055K90FKTA CRCW08051K91FKEA CRCW0805365RFKEA Panasonic: ERA8AED103V KOA: HV732BTTD1002F CRCW08058K20FKTA CRCW080523K20FKTA CRCW08054K32FKTA Panasonic: ERA8AED824V KOA: HV732BTTD8203F Vishay: CNS020-015KL Panasonic: ERA8AED124V KOA: HV732BTTD1203F MicroMELF Walsin: WR08X4700FTL CRCW120615K0FKTA Vishay: CRCW080556K0FKTA Infineon: ICE2PCS01 Linear Tech: LT6231CS8 TI: REF200AU ST: L78M05CDT P95x Value Qty LED, 0805, GREEN TMLM 04115 SCMI10 470nF/250VAC MKP-336 47uF/35V, 6.3x6.3 2 1 1 2 1 1nF, 0805, 10%, X7R 1 100nF, 0805, 10%, X7R B43508-A5567-M067 15 1 1uF, 0805, 10%, X7R 470pF, 1206, 5%, NPO 1 3 10nF, 0805, 10%, X7R SCMI20 P600M 250V / 6A PTF / 15 BS / 140NA B82725-S2602-N41 AK100/4DS-10.0V B82615-B2602-1 D.E. 06ME2 B57237S0509M051 3.3, 0805, 1%, 10ppm 300K, 1206, 1%, 10ppm 220, 0805, 1%, 10ppm 100K, 0805, 1%, 10ppm 82K, 0805, 1%, 10ppm 35K, 0805, 1%, 10ppm 270K, 1206, 1%, 10ppm 200K, 1206, 1%, 10ppm 47K, 0805, 1%, 10ppm 5.9k, 0805, 1%, 10ppm 1.9k, 0805, 1%, 10ppm 365, 0805, 1%, 10ppm 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4 2 2 2 10K, 1206, 1%, 10ppm 8.2k, 0805, 1%, 10ppm 23.2k, 0805, 1%, 10ppm 4.32k, 0805, 1%, 10ppm 3 2 2 2 820K, 1206, 1%, 10ppm CNS020-015KL 4 1 120K, 1206, 1%, 10ppm 1.2K, 0805, 1%, 10ppm 470, 0805, 1%, 10ppm 15K, 1206, 1%, 10ppm 56K, 0805, 1%, 10ppm ICE2PCS01 LT 6231CS8, LT6231CS8 REF200, SOIC8 L78M05 P95x 2 1 1 1 1 1 2 1 1 1 Table 3: Bill of material Highlighted positions have to be assembled EVA P95x for flowIPM 1B Page 22 of 22