Application Note AN 2010-04 V1.0, March 2010 AN2010-04 MA040E12_EVAL – Isolated Gate Driver Power Supply and Logic Interface for MIPAQTM Serve IFAG IMM INP M AE N 2010-03 r 2009 Application Note AN 2010-04 V1.0, March 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. 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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. AN2010-04 Revision History: 2010-04, 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 MA040E12_EVAL – Isolate Gate Driver Power Supply Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve Table of contents 1 INTRODUCTION ........................................................................................................................ 4 1.1 Part number explanation ......................................................................................................... 5 2 DESIGN FEATURES ................................................................................................................. 5 2.1 Main features ............................................................................................................................ 5 2.2 Key data..................................................................................................................................... 6 2.3 Mechanical dimensions ........................................................................................................... 6 2.4 Interconnections between MA040E12_EVAL Board and MIPAQTM serve........................... 7 2.5 Logic Signal Connections to MIPAQTM serve ........................................................................ 7 2.6 Power Signal Connections to MIPAQTM serve ....................................................................... 8 2.7 Main Connector for external control unit............................................................................... 9 3 FUNCTIONALITY OF THE BOARD ........................................................................................ 10 3.1 Building blocks....................................................................................................................... 10 3.1.1 The DC-DC converter......................................................................................................... 11 3.1.2 Isolation Capabilities ......................................................................................................... 11 3.1.3 Locking mechanism........................................................................................................... 12 3.1.4 Output characteristics of the voltage source.................................................................. 12 3.1.5 On Board LEDs................................................................................................................... 14 3.1.6 Further Features................................................................................................................. 15 4 SCHEMATIC AND LAYOUT OF MA040E12 .......................................................................... 15 4.1 Schematics.............................................................................................................................. 16 4.2 Layout ...................................................................................................................................... 19 4.3 Bill of Material - MA040E12_EVAL ........................................................................................ 20 5 HOW TO ORDER EVALUATION BOARDS............................................................................ 22 6 REFERENCES ......................................................................................................................... 22 3 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQTM Serve 1 Application Note AN 2010-04 V1.0, March 2010 Introduction The MA040E12_EVAL isolated gate driver power supply and logic interface board as shown in Figure1 was developed to support customers during their first steps designing applications with the MIPAQTM serve modules. The MA040E12 module power supply boards are available from Infineon in small quantities. Functions and 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 described in this application note for production. The design of the MA040E12 was performed with respect to the environmental conditions described as main features in this document. The requirements for lead-free reflow soldering 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 ambient temperature operating range or lifetime. The boards provided by Infineon are subjected to functional testing only. Due to their purpose, the evaluation boards are not subjected to the same procedures regarding Returned Material Analysis (RMA), Process Change Notification (PCN) and Product Discontinuation (PD) as regular products. See legal disclaimer and warnings for further restrictions on Infineon warranty and liability. Figure 1 The Module Power supply board 4 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 and Logic Interface for MIPAQTM Serve 1.1 V1.0, March 2010 Part number explanation The notation of this evaluation has to be interpreted as explained in the following table MA 040 E12_EVAL MA Module Adapter board 040 Four voltage sources E12 Maximum blocking voltage 1200V EVAL 2 Evaluation Board Design features Electrical features of the evaluation board and mechanical dimensions including necessary interface connections are presented in following sections. 2.1 Main features The MA040E12_EVAL module Power supply board offers the following features: • • • • • Four isolated unsymmetrical voltage sources, -8V, GND, +16V each One logic interface with: • 6 PWM-Channels • Fault signal for desaturation monitoring • Ready signal for under voltage monitoring • Reset via connector X2 or push button S1 • Output of the temperature measurement signal Safety off to avoid accidentally turn on during the standby of the equipment Possibility to control each IGBT with optional DIP switch array PCB is designed to fulfill the requirements of IEC61800-5-1, pollution degree 2, overvoltage category III 5 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve 2.2 Key data All values given in the table bellow are typical values, measured at ambient temperature TA = 25 °C. Table 1 General key data and characteristic values min Parameter Main DC voltage supply VCC Main input current IG Positive output driver supply voltage Negative output driver supply voltage Positive output driver supply current Negative output driver supply current Operating temperature, Top Storage temperature, Tsto 2.3 -40 -40 Typ 15 550 16 -8 90 100 Max 17 +85 +85 Mechanical dimensions The MA040E12_EVAL board integrates the power supply and logic interface combined on one PCB. It is also possible to use the power supply part or the logical part independently. Figure 2 Dimensions of the MA040E12 MIPAQTM Serve Power supply board 6 Unit V mA V V mA mA °C °C N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve 2.4 Interconnections between MA040E12_EVAL Board and MIPAQTM serve Interconnections between the MA040E12_EVAL Board and MIPAQTM serve as shown in Figure 3 are also depicted in section 5 of AN2009-07. To simplify the first steps of designing, one set of connecting wires is included in the evaluation kit. Figure 3 2.5 Assembly of MA040E12_EVAL and MIPAQTM serve Logic Signal Connections to MIPAQTM serve Connector X3 as shown in Figure 4 is for the logical connection between the power supply board and the MIPAQTM serve. Detailed information about the pins are given in Table 2. 22 2 Figure 4 21 1 Logic connections between MA040E12 and MIPAQTM serve Pin X1.1 X1.2 X1.3 X1.4 X1.5 X1.6 X1.7 X1.8 X1.9 X1.10 X1.11 Table 2 Label IN+_B1 IN+_B2 /RST IN+_B3 GND /FLT_B GND RDY_B GND Temp GND Pin X1.12 X1.13 X1.14 X1.15 X1.16 X1.17 X1.18 X1.19 X1.20 X1.21 X1.22 Label + 5V GND RDY_T GND /FLT_T GND IN+_T3 GND IN+_T2 GND IN+_T1 Logic connector signals description 7 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve 2.6 Power Signal Connections to MIPAQTM serve 1) The connector X1 as shown in Figure 5 is the power supply output to the MIPAQTM serve. Detailed information about the pins are given in Table 3. 21 1 Figure 5 22 2 Power supply connections between MA040E12 and MIPAQTM Serve Pin X1.1 X1.2 X1.3 X1.4 X1.5 X1.6 X1.7 X1.8 X1.9 X1.10 X1.11 Table 3 Label GND_T3 NC - 8V_T3 +16V_T3 NC NC GND_T2 +16V_T2 -8V_T2 NC NC Pin X1.12 X1.13 X1.14 X1.15 X1.16 X1.17 X1.18 X1.19 X1.20 X1.21 X1.22 Label NC GND_T1 +16V_T1 - 8V_T1 NC NC NC + 16V_B - 8V_B GND_B NC Power connector signals description 8 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve 2.7 Main Connector for external control unit Connector X2 as shown in the Figure 6 is for the logical connection between the external control unit and the power supply board. Further information about the pins are given in Table 4. 2 16 Figure 6 Main connector from external control unit to MA040E12 Pin X2.1 X2.2 X2.3 X2.4 X2.5 X2.6 X2.7 X2.8 Table 4 Label U_TOP U_BOT V_TOP V_BOT W_TOP W_BOT /T_FLT Pin X2.9 X2.10 X2.11 X2.12 X2.13 X2.14 X2.15 X2.16 T_RDY Label /B_FLT B_RDY T_B_/RST TEMP + 5V GND_S T_PWR_OFF T_PWR_OFF + Main connector signals description 9 1 15 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQTM Serve 3 Functionality of the Board 3.1 Building blocks Application Note AN 2010-04 V1.0, March 2010 The important functional blocks of the MA040E12 as shown in Figure 7 are described in Table 5. The MA040E12 is especially designed to work in conjunction with the MIPAQTM serve modules. A B C H D E F G I J K L Linear regulator for internal 5V power supply for the logic primary side. This can be used if an external +5V supply does not exist. Jumper to be set in case the internal 5V supply is used. Connector for the main power supply. Safety relay. Connector for the control of the safety relay. Connector to the microcontroller unit. Channel selection utilizing DIL switch. Reset switch. DC-DC converter. Functional Isolation using ADUM1210. Logic connector to MIPAQTM serve. Connector of the power supply to MIPAQTM serve. Table 5 Description of building blocks Figure 7 Figure 7 Location of building blocks 10 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve 3.1.1 The DC-DC converter The MA040E12_EVAL offers five separated voltage sources, which are galvanically isolated from the primary side and from each neighboring voltage source. Three separated unsymmetrical voltage sources supplies the three top IGBTs. One unsymmetrical voltage source supplies the three bottom IGBTs and one unipolar voltage source supplies the primary logic side of MIPAQTM serve. The isolation characteristic of the transformers Tr1, Tr2 and Tr3 meet the Isolation requirement for 1200V application according to IEC61800-5-1. Each transformer allows a power transmission up to 2.2W and delivers two unsymmetrical voltage sources of -8V / +16V on the secondary side. Power supply TR1 +5V Isolated logic supply +16V Bottom GND Bottom -8V Bottom Relay for locking mechanism TR2 +16V_TopW GND_TopW -8V_TopW TR3 Linear Voltage regulators on positive output voltage. Figure 8 3.1.2 +16V_TopV GND TopV -8V_TopV +16V TopU GND_TopU -8V_TopU Architecture of the DC-DC power supply Isolation Capabilities The configuration of the MIPAQTM serve offers a functional isolation. Depending on the isolation needed for a given application, a further basic isolation has to be implemented on the MA040E12_EVAL increasing the isolation to higher safety degree like reinforced isolation. The isolation between the primary and the secondary side of the DC-DC converter is achieved through the transformers Tr1, Tr2 and Tr3. 11 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve 3.1.3 Locking mechanism For some applications it is necessary to avoid the accidental operation of equipment during the standby. One way to achieve this is to cut off the power supply of the top IGBT drivers by the safety relay contact P1 Figure 9. The jumper J1 is set as default. Jumper J1 needs to be removed if this functionality is used. The status of P1 can be observed over the contact P2 for an external monitoring. P2 is available on pin 215 and 216 of connector X2 The relay of K1 can be activated by 15V / 60mA using the connector X5. Figure 9 3.1.4 Circuit of locking mechanism Output characteristics of the voltage source The output power and output voltage of the MA040E12 board as shown in Figures 10 and 13 are varying as a function of the switching frequency of the IGBT at 125°C MIPAQTM serve base plate temperature. The variation of the negative output voltage shown on Figure 10 has no influence on the switching behavior of the MIPAQTM serve. MA040E12 negative output voltages vs. switching frequency 0 5 10 fsw [kHz] 15 20 25 -vout [V] -8,3 -8,5 -8,7 V-_T1 [V] V-_T2 [V] Figure 10 V-_T3 [V] V-_B1 [V] V-_B2 [V] Negative output voltages vs. switching frequency 12 V-_B3 [V] N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 and Logic Interface for MIPAQTM Serve V1.0, March 2010 The positive output voltages of the top channel IGBTs are maintained constant at +16V through adjustable linear regulator as depicted in Figure 11. The negative output voltages are not regulated. Figure 11 Voltage regulators for High-Side Supply, T1 as an example The positive output voltages of the bottom channel IGBTs are maintained constant at +16V through adjustable linear regulator as depicted in Figure 12. The negative output voltages are not regulated. Figure 12 One voltage source for the three Bottom IGBTs 13 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve The power requirement of the bottom side as shown in Figure 13 is higher than the power dissipation of the high side drivers. The reason is that the circuit of the temperature measurement is also supplied by the power supply of the bottom side drivers. For the analysis of the base plate temperature of MIPAQTM serve please refer to the AN2009-07. MA040E12 output power vs. switching frequency 1,2 1 Pout [W] 0,8 0,6 0,4 0,2 0 0 5 P_T1 [W] 10 P_T2 [W] Figure 13 3.1.5 15 fsw [kHz] P_T3 [W] P_B1 [W] 20 P_B2 [W] 25 P_B3 [W] Output power vs. switching frequency On Board LEDs The MA040E12_EVAL Board provides 6 yellow LEDs VCC_T1, VEE_T1, VCC_T2, VEE_T2, VCC_T3, VEE_T3, VCC_B, VEE_B to indicate that the power is turned on. The desaturation monitoring of the top and bottom channel diodes /FLT_T, /FLT_B are switched on if desaturation failure occurs on one of the 6 IGBTs. The RDY_T and RDY_B LEDs are ON if the MIPAQTM serve is sufficiently powered. Figure 14 Indicators of power and driver status 14 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQTM Serve 3.1.6 Application Note AN 2010-04 V1.0, March 2010 Further Features The MA040E12_EVAL offers the possibility to switch each IGBT separately using the SMT DIL switch. In this case the switching signal has to be supplied by jumper JP1. This is intended to allow simple double pulse testing. The DIL switch is not included by default. Figure 15 Channel selection The primary logic supply voltage of the power supply board can be supplied from the main supply voltage +15V shown on Figure 17 or can be externally applied to the connector X2 pins 213 and 214. In case of internal supply, Jumpers J2 and J3 have to be set. Figure 16 4 Supply of primary Logic Schematic and Layout of MA040E12 To meet the individual customer requirements and make the evaluation board a basis for further developments or modifications, all necessary technical data like schematic, layout and components are included in this chapter. 15 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 and Logic Interface for MIPAQTM Serve 4.1 Schematics Figure 17 Power supply bottom and logical output side 16 V1.0, March 2010 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 and Logic Interface for MIPAQTM Serve Figure 18 Power supply bottom and Top_U 17 V1.0, March 2010 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQTM Serve Figure 19 Power supply Top_V and Top_W Figure 20 Power supply Top_V and Top_W 18 Application Note AN 2010-04 V1.0, March 2010 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQTM Serve 4.2 Layout Figure 21 Figure 22 Top layer Bottom layer 19 Application Note AN 2010-04 V1.0, March 2010 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQTM Serve 4.3 Figure 23 Vcc layer Figure 24 GND layer Application Note AN 2010-04 V1.0, March 2010 Bill of Material - MA040E12_EVAL The tolerances for resistors should be less or equal ±1 %, for capacitors of the type C0G less or equal ±5 % and for capacitors of the type X7R less or equal ±10 %. 20 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 Application Note AN 2010-04 V1.0, March 2010 and Logic Interface for MIPAQTM Serve Type Value / Type Package QTY capacitor 100n/25V/X7R C603 14 capacitor 100n/50V/X7R C603 2 capacitor 100p/50V/C0G C603 8 capacitor 4µ7/25V/X7R C1206 32 capacitor 3µ3/25V/X7R C1206 3 diode BAT165 SOD323R 23 Recommended Manufacturer Diode GF1G DO-214BA 1 C22, C23, C24, C25, C26, C27, C28, C31, C32, C33, C34, C35, C36, C37 C4, C12 C4T1, C4T2, C4T3, C7, C7B, C9, C15, C17 C1, C1B1, C1L, C1T1, C1T2, C2B, C2L,C2T1, C2T2, C3B,C3T1, C3T2, C4B, C5B, C6, C6B, C8, C9T1, C10, C10T1, C11, C11T1, C14, C16, C18, C19, C20, C21, C2, C3, C29, C30 C38, C39, C40 D1, D1B, D1L, D1R1, D1R2, D1T1, D1T2, D2, D2B, D2L, D2T1, D2T2, D2T3, D3B, D3T1, D3T2, D3T3, D4B, D4T1, D5B, D6B D3 capacitor 1µ/25V/X7R C805 2 C5, C13 safety relay V23047-A1012-A501 1 K1 resistor 0R15 R805 3 R7, R12, R49 Murata Tyco Electronics - resistor 56k R603 1 R1B - resistor 10k R805 5 R32, R33,R34, R36, R37 - resistor 330R R603 1 R4B - resistor 100k R603 3 - resistor 10k R603 16 JP1 1 R1T1, R1T2, R1T3 R4T1, R4T2, R4T3, R13, R14, R15, R16, R31, R35, R38, R39, R40, R41, R42, R43, R3B JP1Q resistor 10R R603 1 R30 - resistor 47R R603 3 R5T1, R5T2, R5T3 - jumper Murata Murata Murata Murata Murata Infineon - - resistor 120k R603 3 R3T1, R3T2, R3T3 - resistor 150R R1206 1 R44 - resistor 15R R603 4 R4, R5, R9, R10 - resistor 2k R805 4 - resistor 1k R805 - resistor 100R R1206 1 R21, R23, R25, R27 R17, R18, R19, R20, R22, R24, R26, R28, R29 R46 transformer T60403-D4615-X054 D4615-X054 3 TR1, TR2, TR3 VAC resistor 2k2 R603 2 - resistor 0R R805 8 resistor 68k R603 2 semiconductor ADUM1210 SOIC08 7 R6, R11 R1, R2, R45, R48, R2B, R2T1, R2T2, R2T3 R3, R8 IC3, IC4, IC5, IC6, IC7, IC8, IC9 S1 Analog Devices - switch semiconductor surface mount DIP switch series 1 Name Part 9 B3W-1000 SN7002N CTS-219-06J_NC 1 - - SOT23 1 T9 Infineon 219-06J 1 S2 - Not connected 21 N 2010-03 MA040E12_EVAL – Isolate Gate Driver Power Supply r 2009 and Logic Interface for MIPAQ TM Application Note AN 2010-04 V1.0, March 2010 Serve 219 SMT connector connector 2) connector Molex Microfit 22 pins 43045-2215 1 X1 Molex Tyco Electronics Molex connector MPT2 2POL254 2 X4, X5 Phoenix transistor BC846 SOT23 2 T7, T8 - transistor BC856 SOT23 2 T5, T6 - transistor BSL302SN TSOP6 4 T1, T2, T3, T4 Infineon voltage regulator IFX25401 IR2085STR_PBF or AUIR2085S TO252-5 1 IC2B SO08 2 Infineon International rectifier semiconductor Molex MilliGrid 22 pins Tyco Micro-Match 16 pins 3) 4) 087832-2220 1 X3 8-188275-0 1 X2 IC1, IC2 LEDCHIPLED_0805_YELLOW 0805 8 semiconductor LEDCHIPLED_0805_RED 0805 2 +16V_B, +16V_T1, +16V_T2, +16V_T3, 8V_B, -8V_T1, -8V_T2, 8V_T3 /FLT_B, /FLT_T semiconductor LEDCHIPLED_0805_GREEN 0805 2 RDY_B, RDY_T - semiconductor - semiconductor LP2951CM SOIC08 3 IC1T1, IC1T2, IC1T3 National voltage regulator ZSR500G SOT223 2 U1, U2 Zetex mechanical Corner Part 4 CP1, CP2, CP3, CP4 - jumper 2 J2, J3 - jumper 1 JP1 - Size: 89x116,5x121mm; material:FR4; PCB 1 Layers - Cu : 4x35ìm; - Isolation: 3x0,5mm; flammability: UV94V0 5 How to order Evaluation Boards Every Evaluation 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 these data is subjected to the disclaimer given in this AN. Please contact: [email protected] IFX order number for MA040E12_EVAL: 34680 6 References 1) AN2009-07: MIPAQ™ serve Module with adapted driver electronics Infineon AG Warstein (Germany) 2 The corresponding parts can be found by Molex as IDT connector and optionaly strain relief. Part number 087682293 resp. 0875691022 3 4 The corresponding connector can be found by Tyco Electronics. Part number 0430252200 The corresponding parts can be found by Molex as crimp Housing and crimp terminal. Part number 0430252200 resp. 0430300003 22