Application Note AN 2010-03 V1.0, May 2010 AN2010-03 7ED020E12-FI-U1 – Evaluation Board for SmartPIM1 Modules with 2ED020I12-FI driver ICs IFAG IMM INP M AE N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Edition 2010-05-07 Published by Infineon Technologies AG 59568 Warstein, Germany © Infineon Technologies AG 2010. 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 lifesupport 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. AN2010-03 Revision History: date(2010-08-13), V1.0 Previous Version: none Page: Subjects (major changes since last revision) all: First release Author: Alain Siani(IFAG IMM INP M 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]] 2 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 Table of contents 1 Introduction ...................................................................................................................................4 2 2.1 2.2 2.3 2.4 Design features .............................................................................................................................5 Main features .................................................................................................................................5 Pin assignment..............................................................................................................................5 Mechanical dimension..................................................................................................................6 Mounting of the SmartPIM1 Module............................................................................................6 3 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Application note ............................................................................................................................7 Switching behavior .......................................................................................................................8 Over current and short circuit protection ..................................................................................9 Brake chopper .............................................................................................................................10 Overtemperature protection ......................................................................................................10 /Fault output ................................................................................................................................10 RMS current and DC link voltage limits....................................................................................10 Indication of the surge current at turning on of the board.....................................................10 Cooling condition .......................................................................................................................10 4 4.1 4.2 4.3 Schematic, Layout and Bill of Material .....................................................................................11 Schematic ....................................................................................................................................11 Layout ..........................................................................................................................................14 Bill of material .............................................................................................................................16 5 How to order the evaluation board............................................................................................17 Part number explanation 7ED 020 E12 -FI -U1 Package SmartPIM1 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. 3 N 2010-03 r 2009 Evaluation Board for SmartPIM1 1 Application Note AN 2010-03 V1.0, May 2010 Introduction The Evaluation Driver Board 7ED020E12-FI-W2 for SmartPIM1 modules shown 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 Infineon’s warranty and liability. Figure 1 The Evaluation Board 7ED020E12-FI-U1 with SmartPIM1 4 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 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-U1 contains four coreless transformer ICs 2ED020I12-FI from Infineon and one Infineon SmartPIM1 module, which contains a B6 diode rectifier, a brake chopper and six IGBTs for the inverter. Figure 2 shows the functional groups of the evaluation board. X5 Terminals U, V, W Terminals L1, L2, L3 J1 Driver 1 Logic selector Driver 2 IGBT Module Driver 3 Timer Driver 4 X4 Figure 2 Brake DC-Link Functional groups of the evaluation board 7ED020E12-FI-U1 The Evaluation board provides following main features: - Rectifier, brake chopper and inverter integrated in one SmartPIM1 module. - Functional isolation between high side and low side with coreless transformer technology. - Short circuit and overcurrent protection. - Overtemperature protection. - Overvoltage protection. 2.2 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: 5 N 2010-03 r 2009 Evaluation Board for SmartPIM1 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 Application Note AN 2010-03 V1.0, May 2010 Mechanical dimension Figure 3 Mechanical dimension of 7ED020E12-FI-U1 2.4 Mounting of the SmartPIM1 Module A unique feature of SmartPIM1 is the combination of press fitting and mounting to the heatsink within one step as described in AN2009-09. 6 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 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 high-side 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 SmartPIM1 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 Active Low/High settings µController J1 X5-7 (Enable) OutL, OutH X5-1…X5-6=0 Jumper on pin 1-2 (Active LOW) 0 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, overcurrents and overtemperature. 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 = R17 • C32 • 0,69 and for voltage bellow 1/3 • Vcc. In case the LOW signal at the trigger input remains the timer will wait until the trigger input receives a HIGH signal. 7 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 3.1 Switching behavior The switching characterization with a module FP35R12U1T4 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 6Ω gate resistor value. 100ns/div 100ns/div Vge 5V/div Vge 5V/div Ic 10A/div Ic 10A/div Vce 150V/div Vce 150V/div Figure 4 Turn on (left) and turn off (right) with FP35R12U1T4 behavior @25°C 100ns/div 100ns/div Vge 5V/div Ic 10A/div Ic 10A/div Vge 5V/div Vce 150V/div Vce 150V/div Figure 5 Turn on (left) and turn off (right) with FP35R12U1T4 behavior @125°C 100ns/div 100ns/div Vge 5V/div Vge 5V/div Ic 10A/div Ic 10A/div Vce 200V/div Vce 200V/div Figure 6 Turn on (left) and turn off (right) with FP35R12U1T4 behavior @150°C With the diagram the switching losses Eon and Eoff at 25°C, 125°C and 150°C can now be calculated. 8 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 Table 3 Switching energy with FP35R12U1T4 Temperature Eon datasheet @ Ls = 35nH Eon @ Ls = 83nH Eoff datasheet @ Ls = 35nH Eoff @ Ls = 83nH @25°C 1.9mJ 2.5mJ 2mJ 2mJ @125°C 2.9mJ 3.5mJ 2.9mJ 2.96mJ @150°C 3.15mJ 3.9mJ 3.2mJ 3.25mJ 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 current and short circuit 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 overcurrent-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: Vge 5V/div 100ns/div Vge 5V/div Vce 150V/div 100ns/div Vce 150V/div Ic 50A/div Ic 50A/div Figure 7 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 1 The OP3 means the operation amplifier integrated in IC3. The same designation is used for the other CPs and OPs. 9 N 2010-03 r 2009 Evaluation Board for SmartPIM1 Application Note AN 2010-03 V1.0, May 2010 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 Overtemperature protection Based on the built-in NTC in the module the bottom copper plane temperature will be monitored and in case of overtemperature 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 overtemperature 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, overcurrent or overtemperature the /Fault Pin (X5-8) will be switched to low to report an error to the microcontroller. After a definable delay time t=R17*C32 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. 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. 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 sometime 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. 10 N 2010-03 r 2009 Evaluation Board for SmartPIM1 4 Application Note AN 2010-03 V1.0, May 2010 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 Figure 8 Input stage Figure 9 Driver stage 11 N 2010-03 r 2009 Evaluation Board for SmartPIM1 Figure 10 Power stage Figure 11 Fault timer 12 Application Note AN 2010-03 V1.0, May 2010 N 2010-03 r 2009 Evaluation Board for SmartPIM1 Figure 12 OV OC SC and OT protection circuit 13 Application Note AN 2010-03 V1.0, May 2010 N 2010-03 r 2009 Evaluation Board for SmartPIM1 4.2 Layout Figure 13 Layout of Top layer Figure 14 Layer 2 14 Application Note AN 2010-03 V1.0, May 2010 N 2010-03 r 2009 Evaluation Board for SmartPIM1 Figure 15 Layer 3 Figure 16 Layout of bottom layer 15 Application Note AN 2010-03 V1.0, May 2010 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 4.3 Bill of material Type Qty value package size name part Jumper 1 Capacitor 1 1µ 1206 C33 Capacitor 5 1n 1206 C21, C27, C28, C34, C36 Capacitor 3 2.2µ Tantalum, size D C6, C12, C18 J1 Connector 1 9POL2.54 9POL2.54 X5 Capacitor 3 10n 1206 C29, C31, C35 Capacitor 1 33n 1206 C26 Capacitor 1 47µ CPOL-EUE2,5-6E C23 Capacitor 9 100n C-EUC1206K C4, C10, C16, C24, C25, C30, C32, C37, C38 Capacitor 4 4u7 C-EUC1206K C5, C11, C17, C22 Capacitor 11 330p C-EUC1206K C1, C2, C3, C7, C8, C9, C13, C14, C15, C19, C20 Connector 4 2POL2.54 2POL2.54 X1, X2, X3, X4 Connector 10 Tab terminals, type Vogt 3866G.68 (F061.080) B, L1, L2, L3, N, P, P1, U, V, W Resistor 3 10R R1206 from TT Electronics, series: PWC. R64, R65, R66 Resistor 3 2R2 NTC_EPCOS R50, R51, R52 Resistor 3 2k 1206 R16, R34, R48 Resistor 1 3.3k 1206 R44 Resistor 1 5.1k 1206 R18 Resistor 1 8.2k 1206 R46 Resistor 1 9.1k 1206 R21 Resistor 3 10k 1206 R22, R25, R49 Resistor 1 13k 1206 R27 Resistor 1 15k SOMC1601 RN1 Resistor 10 15k 1206 R9, R10, R11, R12, R13, R14, R15 Resistor 1 18k 1206 R30 Resistor 1 18m 5020 R8 Resistor 1 22k 1206 R45 Resistor 1 27k 1206 R28 Resistor 1 33k 1206 R33 Resistor 1 56k 1206 R35 Resistor 1 82k 1206 16 R20 N 2010-03 r 2009 Application Note AN 2010-03 V1.0, May 2010 Evaluation Board for SmartPIM1 Resistor 11 100R 1206 R53, R54, R55, R56, R57, R58, R59, R60, R61, R62, R63 Resistor 1 100k 1206 R23 Resistor 1 150k 1206 R47 Resistor 2 470R 1206 R19, R31 Resistor 1 560k 1206 R17 Resistor 8 680k 1206 R36, R37, R38, R39, R40, R41, R42, R43 820R 1206 R26 Semiconductor 4 2ED020I12-F PG-DSO-18-2 IC1, IC2, IC3, IC4 Semiconductor 2 74AC86D 14-SOIC IC5, IC6 Semiconductor 1 78L05 SO-8 IC7 Semiconductor 5 BCR533 SOT23 Q1, Q2, Q3, Q4, Q5 Semiconductor 7 BZV55C16 D-SOD-80 D4, D5, D6, D7, D8, D9, D10 Semiconductor 1 LMC555 SO-8 IC8 Semiconductor 2 LS103A D-SOD-80 D12, D13 Resistor 1 Semiconductor 3 STTA112U SMB D1, D2, D3 Semiconductor FP35R12U1T4 SartPIM1 IGBT IFX1 Box 1 Gate resistor list Part type U1T4 Recommended gate resistor FP25R12U1T4 FP35R12U1T4 5 Package Name part 10R 1206 R1, R2, R3, R4, R5, R6, R7 6R 1206 R1, R2, R3, R4, R5, R6, R7 How to order the evaluation board Every Evaluation Driver Board has its own IFX order number and can be ordered via your Infineon Sales Partner. Information can also be found at the Infineons Web Page: www.infineon.com CAD-data for the board described here are available on request. The use of this data is subjected to the disclaimer given in this AN. Please contact: [email protected] IFX order number for 7ED020E12-FI-U1: 35027 17