Download DIP IPM Vers.3 Demo Board (1200V) Manual

Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
1200V DIP IPM (PS2205X)
EVALUATION BOARD
(EVBPS220XX)
 OHM Elektronik
1200V DIP IPM EVALUATION BOARD (PS2205X)
The 1200V DIP IPM evaluation board is intended to functionally test the features and the
performance of the Mitsubishi 1200V transfer mold DIP IPM family. This new DIP IPM
family contains of 4 new products: PS22052 (5A), PS22053 (10A), PS22054 (15A) and
PS22056 (25A). The control terminal pin assignment of the board is compatible with the
pinning of the 600V MiniDIP IPM version 3 evaluation board although a standard 2,54mm
pin-header is used instead of the JST connector as default. Such 2,54mm pin-headers are
available as a world wide standard. All power terminals are accessible through FASTON
4,8mm connectors. Simply providing 15V isolated supply voltage, MCU/DSP control signals
and a DC-link voltage makes the evaluation board operable. For load tests it is strongly
recommended to provide a suitable cooling system in order to keep the temperature at the case
reference point clearly below 100°C.
Page 1 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
WARNING – read carefully !
This evaluation board is intended to be used by qualified personnel only. High voltage and the
lack of a safety isolation will be dangerous during the entire operation. It is recommended to
operate the evaluation board with isolated supplies exclusively.
Never touch the board or any connected equipment when a voltage is applied to it.
Residual voltage across the snubber capacitor may store high voltages for a very long time
after the operation of the evaluation board. We recommend all the capacitors on the board to
be discharged after the operation of the board to avoid damage to any connected hardware and
to prevent from hazardous electrical shocks.
Contents:
#
A.
0.
1.
2.
3.
4.
5.
6.
Topic
Introduction
Safety advise
Required external hardware for the operation of the evaluation board
On the evaluation board
Schematic of the evaluation board
PCB layout and considerations
Bill of material
Disclaimer
page
2
3
4
5
8
10
11
Page 2 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
1. Required external hardware for the operation of the evaluation board:
Figure 1: The 1200V DIP IPM evaluation board and its required external hardware
The evaluation board (Mitsubishi order no EVBPS220XX) shown in green colour does not
comprise the 1200V DIP IPM itself and its specific shunt resistors for short circuit (SC)
protection. Table 1 indicates the DIP IPM range from 5A to 25A and their individual
corresponding recommended shunt resistor range.
The control part of the evaluation board should be supplied by a stabilized 15V DC / 100mA
voltage source as shown in yellow colour.
A low inductive power supply of the IGBT is established by connecting the electrolytic
capacitors (DC-link capacitors) with the help of short (~8cm (~3 inch)) twisted cables to the
“P” and “N” terminals of the evaluation board. The DC-link capacitors are fed by a rectifier
for example through an isolated 3~ variable transformer to limit the surge current during
power up.
The control interface of the evaluation board is capable of operating with 5V logic signals
that can be generated by microprocessors or 5V digital signal processors (DSP). The 6 control
signal lines and the fault output (FO) line as well as the GND reference should be connected
between the MCU/DSP board and the 1200V DIP IPM evaluation board. The fault output of
the IPM is an “open drain” type that requires a pull up resistor of about 10kΩ tied to the
supply voltage of the control signals. This pull up resistor is placed on the board and can be
activated by connecting the “5V” terminal of the control signal pin-header to the positive
supply of the MCU/DSP board.
Page 3 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
2. On the evaluation board
 OHM Elektronik
Figure 2: The 1200V DIP IPM evaluation board and its components
All necessary components for a basic operation of the 1200V DIP IPMs using the three open
Emitter topology (and three shunts) for FO purposes are placed on the evaluation board.
These 3 shunts are used for the SC-protection, as well. Table 1 shows the proposed values for
these shunt resistor with reference to the 1200V DIP IPM rating:
Module
PS22052
PS22053
PS22054
PS22056
rated power of the
Irms/leg (dTj=25K, Isc,tripmax [A] proposed shunt
motor (approximately) Tj=125°C,15kHz) [A] (datasheet) resistor value*[Ohm]
800W
1,8
8,5
≥0,15
1,5kW
3,4
17
≥0,075
2,7kW
5,5
25,5
≥0,05
4kW
9,2
42,5
≥0,03
* assuming Vf = 0,7V (D1…D3), VSC(ref) = 0,48V (DIP IPM), ISC = (Vf + VSC(ref))/Rshunt
Table 1: 1200V DIP IPM, approximate motor power rating, rms current per leg, the max SCtrip current stated in the datasheet and the suggested value for the shunt resistor.
The compliance with the specified Isc,tripmax must be verified under the individual
application conditions to ensure a reliable operation of the IPM during SC. Standard SMD
shunt resistors up to size 2817 (manufacturer: YAGEO, Isabellenhuette…) fit into the
footprint provided on the PCB.
Page 4 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
 OHM Elektronik
Figure 3: Schematic of the DIP IPM 1200V evaluation board
3. Schematic of the evaluation board
Page 5 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
The schematic shows the flexibility of the evaluation board to test components in conjunction
with the DIP IPM. The board is as default populated with the standard pin-header counting 10
pins with a pitch of 2,54mm. However it is possible to place the JST connector - introduced
on the recent MiniDIP IPM version 3 evaluation board. A dedicated footprint for this JST
connector is provided on the EVBPS220XX to keep the compatibility with previous
generation of Mitsubishi evaluation boards. The pin’s function is printed on the PCB itself for
easy tracking and is redundant with the naming of the pins of the corresponding datasheet of
the 1200V DIP IPM.
The control signals wiring from MCU/DSP to the pin-header of the evaluation board as well
as from the pin-header to the DIP-IPM terminals should be as short as possible to avoid EMI
disturbances and unwanted switching of the IPM. The same precautions – tracks as short as
possible - have been applied to the board design itself.
The bootstrap supply area contains of an ultrafast (trr=75ns) 1200V/1A diode, a charge
current limiting resistor and a pair of electrolytic and ceramic capacitor. The diodes may be
housed in a surface mounted “SMB” package or in the standard wired “SOD57” or “DO-41”
package. The size of the electrolytic bootstrap capacitor varies with the type of application.
The electrolytic bootstrap capacitor area provides sufficient space to place SMD capacitors up
to 47µF/25V to allow the IPM to be operated at very low switching frequencies or for BLDC
applications or with 2-phase modulation PWM strategies operating at low output frequencies.
The voltage across the bootstrap capacitors should never fall below the under voltage
detection level indicated in the datasheet of the 1200V DIP IPM under normal operation. The
compliance with the indicated bootstrap supply voltage can be verified easily at the pins of the
IPM.
The Zener diode D4 (24V/1.3W) prevents the IPM from transient over voltages of the supply
voltage. It can clamp the transient over voltage efficiently to a level that does not harm the
internal LVIC/HVIC of the IPM.
The SC-protection circuit contains of the 3 shunt resistors R5…R7, the 3 diodes D1…D3 ,
R11and the low pass filter network of R9/C8 to blank the recovery peak current of the
opposite freewheeling diode. The proposal for the value of the shunt resistor has been made in
Table 1.
The 3 diodes are operating in an “or” function. Thus, if the voltage drop of any shunt exceeds
the sum of the (temperature dependent) forward voltage drop of the diode (D1 or D2 or D3)
and the input threshold voltage of the SC- detecting comparator of the DIP IPM (typ. 0,48V),
the SC- condition will be detected. The additional forward voltage drop of the diode (Vf) and
its temperature dependency is a sensitive point when selecting the right value of the shunt for
a safe SC protection over a certain temperature range. Therefore it is strongly recommended
to verify the SC- detection level under real application conditions to ensure safe SC operation
within the specified limits of the 1200V DIP IPM and the desired temperature operating range
of the application circuit. A typical operation of the SC-detection circuit using the proposed
diode OR-ing circuitry is shown in figure 4. The SC- operation has become active at 940mV
across the shunt connected to NU. The detection current was Isc,detect = 940mV/ Rshunt.
Page 6 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
Assuming a typical SC-detection level of 480mV (VSC(ref)) at the DIP IPMs comparator input
and neglecting the influence of the R9/C8 delay, the voltage drop of the OR-ing diode must
have been in the range of 460mV at this specific test. The type of diode has an influence on
the performance of the SC detection and it is recommended to prefer low Vf types.
Ch1: u-phase shunt voltage (1V/div), Ch2: v-phase shunt voltage (1V/div), Ch3: w-phase shunt voltage
(1V/div), Ch4: Fo (5V/div)
Figure 4: SC detection circuit: operation of the IPM
In case that the separate current information of the three legs is not required, it is possible to
connect all three open emitters together and to use just a single shunt resistor. Hence, the
diodes D1…D3 and R11 have no function and could be omitted or bypassed respectively. The
value of the SC- detection shunt can be calculated omitting the additional forward drop
voltage of the diode.
To prevent the 1200V DIP IPM from dangerous high voltage spikes, a dedicated snubber
capacitor C6 (0,22µF/1250V) has been populated at the most advantageous position for
highest efficiency. Thus, possible over voltage spikes generated through the stray inductance
of the wiring between DC-link capacitors and the PCB are limited to a level below 1200V.
Minimizing the stray inductance of this wiring by bringing the wires as close as possible
together for example by twisting them will reduce the over voltage spike and ease the work of
the snubber capacitor.
Page 7 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
4. PCB layout:
The PCB has been made using a 1,5mm thick double sided (35µm) FR4 material
 OHM Elektronik
Figure 4: Toplayer
On the top layer all components are placed and most of the signal traces were made.
Page 8 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
Figure 5: Bottomlayer
 OHM Elektronik
The bottom layer is mainly used for supply (GND) and shielding. However the signal traces
from the open Emitters are located here, too.
Page 9 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
5. Bill of material used:
Part
C1
C2
C3
C4
C5
C6
C7
C8
C9
C10
C13
C14
C15
C16
CON6*
CON7
Value
100nF
100nF
100nF
10µF…47µF/25V
10µF…47µF/25V
0,22µF/1250V
100nF
1nF
10µF…47µF/25V
47µF/25V
22nF
100nF
100nF
100nF
JST connector
PINHD-1X10
Package
0805
0805
0805
SMD-C-6,
SMD-C-6,
C27,5B15 CAP
0805
0805
SMD-C-6,
SMD-C-6,
0805
0805
0805
0805
B10P-VH JST VH
1X10 (2,54mm pitch)
D1
D2
D3
D4
D5*
D6*
D7*
D8
D9
D10
BAS21 (or equivalent)
BAS21 (or equivalent)
BAS21 (or equivalent)
Z22...Z24/1,3W
STTH112U (or equivalent**)
STTH112U (or equivalent**)
STTH112U (or equivalent**)
SF1200 (or equivalent**)
SF1200 (or equivalent**)
SF1200 (or equivalent**)
SOT-23
SOT-23
SOT-23
SMA
SMB
SMB
SMB
SOD57 / DO-41 manufacturer: VISHAY
SOD57 / DO-41 manufacturer: VISHAY
SOD57 / DO-41 manufacturer: VISHAY
R1
R2
R3
R4
R5*
R6*
R7*
R9
R11
10R
10R
10R
10k
shunt (ref. table1)
shunt (ref. table1
shunt (ref. table1
1,5k
220R
0805
0805
0805
0805
2817, YAGEO, Isabellenhuette (or equivalent)
2817, YAGEO, Isabellenhuette (or equivalent)
2817, YAGEO, Isabellenhuette (or equivalent)
0805
0805
U
V
W
N
P
17094A
17094A
17094A
17094A
17094A
TYCO/AMP (4,8mm FASTON) (or equivalent)
TYCO/AMP (4,8mm FASTON) (or equivalent)
TYCO/AMP (4,8mm FASTON) (or equivalent)
TYCO/AMP (4,8mm FASTON) (or equivalent)
TYCO/AMP (4,8mm FASTON) (or equivalent)
IPM1* PS2205x
MITSUBISHI ELECTRIC
* not populated
** ultrafast trr=75ns/ Vrrm =1200V
Page 10 of 11
Application note AN2004-31
1200V DIP IPM evaluation board Mitsubishi PS2205X
Disclaimer
We (OHM Elektronik VE TIC) do not warrant that the 1200V DIP IPM evaluation board is
free from claims by a third party of copyright, patent, trademark trade secret or any other
intellectual property infringement. Under no circumstances are we liable for any of the
following:
1. third-party claims against you for losses or damages
2. loss of, or damage to, your records or data; or
3. economic consequential damages (including lost profits or savings) or incidental
damages, even if we are informed of their possibility.
4. We do not warrant uninterrupted or error free operation of the evaluation board and all
related hardware.
5. We have no obligation to provide service, defect correction, or any maintenance for
the 1200V DIP IPM evaluation board.
6. We have no obligation to supply any updates or enhancements to you even if such are
or later become available.
IF YOU USE THIS 1200V DIP IPM EVALUATION BOARD BY CONNECTING ANY
WIRING TO THE PCB YOU AGREE TO THESE TERMS. THERE ARE NO
WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.
Page 11 of 11