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IRMD2231Q
International Rectifier * 233 Kansas Street, El Segundo, CA 90245 USA
IRMD22381Q Demo Board
For 3-phase / 380V motor drives
IR22381Q Demo Board without IGBT Power Module
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IRMD22381Q
IRMD22381Q Demo Board
For 3-phase / 380V motor drives
IRMD22381Q Demo Board
* * * * * * * * * * * * * * * * * Up to 1200V DC-bus capability Up to 25A maximum phase current Optional on-board phase shunt resistors IR22381Q device connected in 3-phase + brake configuration On-board bootstrap supply for high-side gate drive Full protection of phase-to-phase, DC-bus and ground short circuit by monitoring IGBT de-saturation Brake IGBT de-saturation protection Fault feedback to ground level Trimmer programmable dead time Anti-shoot-through management Phase voltage feedback Undervoltage lockout 3.3V digital input/output CMOS compatible IR22381Q can be replaced by IR21381Q
IR22381Q Demo Board (Shown without IGBT Power Module)
Power Module
Standard ECONO2-PIM IGBT module compatible IGBT short circuit rated up to 1200V/25A. Easy to mount heat-sink holes
Introduction
The IRMD22381Q demo board is an evaluation board for IR22381Q gate driver (see device datasheet for details). IRMD22381Q is designed to drive 3-phase power modules with pin-out compatible to ECONO2-PIM. The board can drive AC or Brushless motors using power modules with up to 25A output current. The board is a flexible solution for different applications and can be customized by means reconfigurable components options. The control signals are 3.3V CMOS compatible; three-phase shunt resistor (with sensing pins) can be placed for current loop control; power module short circuits are managed by IR22381Q by synchronization of the IGBTs turn off. Board layout reduces the noise coupling between high and low voltage signals.
IRMD22381Q + Power Module
Application Block Diagram
(Refer to connections section to see the interface pins) This diagram shows the main blocks and connections of the demo board and the external components necessary in a typical motor drive application.
DCbus AC/DC Conveter Low Voltage Power Supply
3-phase half bridge (Power Module)
shunt resistor shunt resistor shunt resistor
IR22381Q
Motor
System Control
3-phase Current Sensor
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IRMD22381Q
Table of contents
INTRODUCTION ...............................................................................................................................................1 Table of contents............................................................................................................................................2 Parameters.....................................................................................................................................................3 The IR22381Q................................................................................................................................................3 The power module .........................................................................................................................................3 Important Notice.............................................................................................................................................3 BOARD CONNECTORS ...................................................................................................................................4 Connection with the system controller ...........................................................................................................4 FAULT logic signal .........................................................................................................................................5 DCF................................................................................................................................................................5 RT+ and RT- ..................................................................................................................................................5 VFHx and VFLx..............................................................................................................................................5 VCC supply pin ..............................................................................................................................................5 VSS ground pin (GND) ..................................................................................................................................5 5V ...................................................................................................................................................................5 Connecting the current sensors .....................................................................................................................6 High power signal connector..........................................................................................................................6 Connecting the power module .......................................................................................................................6 Test Points .....................................................................................................................................................7 TEST BENCH CONNECTION ..........................................................................................................................8 OPERATING DESCRIPTION............................................................................................................................9 Normal operating mode .................................................................................................................................9 Fault management .........................................................................................................................................9 Multilevel board solution ................................................................................................................................9 Precharge of the bootstrapped sections ........................................................................................................9 BOARD CUSTOMIZATION.............................................................................................................................10 Bootstrap circuit ...........................................................................................................................................10 Gate resistances ..........................................................................................................................................10 OTHER EXTRA COMPONENTS ....................................................................................................................11 Desat circuit .................................................................................................................................................11 Clamping Diode for Vs below ground ..........................................................................................................12 RC filter on COM pin ....................................................................................................................................13 Fast diode between gate and supply pin .....................................................................................................13 Zener diode to preserve the IGBT gate .......................................................................................................14 Optional output shunt resistor ......................................................................................................................14 Resistor on vcc ..............................................................................................................................................14 BILL OF MATERIAL .......................................................................................................................................15 SCHEMATIC LAYOUT....................................................................................................................................17 LAYOUT ..........................................................................................................................................................22
Table of figures
Figure 1: TOP image of board ...........................................................................................................................4 Figure 2: LED connection ..................................................................................................................................5 Figure 3: Test bench connection .......................................................................................................................8 Figure 7: Bootstrap circuit................................................................................................................................10 Figure 8: Desat external filter ..........................................................................................................................11 Figure 9: -Vs clamp ..........................................................................................................................................12 Figure 10: COM below ground protection........................................................................................................13 Figure 11: Collector-Gate current protection ...................................................................................................13 Figure 12: Zener clamp for IGBT gate.............................................................................................................14
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IRMD22381Q
Parameters Input Power DC+ DCVCC VSS ICC Output Power Ilmax Control Inputs/Outputs 40 pin connector J1 I/Os
Values
Description, condition DCBus voltage positive with 1200V power module DCbus voltage negative Low voltage power supply. Follow IR22381Q datasheet for supply setting Low voltage ground quiescent Vcc current max phase dc output current see "Board Connectors" section on page 4
0 to 1200V ground 15V typ ground 25 mA (max) 25A @25C
3.3V to 15V compatible
The IR22381Q
The IR22381Q is a high voltage, 3-phase IGBT driver best suited for AC motor drive applications. Integrated desaturation logic provides all mode of overcurrent protection, including ground fault protection. The sensing desaturation input is provided by active bias stage to reject noise. Soft shutdown is predominantly initiated in the event of overcurrent followed by turn-off of all six outputs. A shutdown input is provided for a customized shutdown function. The DT pin allows external resistor to program the deadtime. Output drivers have separate turn on/off pins with two stage turn-on output to achieve the desired di/dt switching level of IGBT. Voltage feedback provides accurate volt x second measurement. For further technical information see the IR22381Q datasheet at http://www.irf.com.
The power module
IRMD22381Q demo board is ECONO2-PIM compatible with standard pin out.
Important Notice
IRMD22381Q demo board is supplied with a tentative Bill of Material suitable for a 1200V/10A@100C power module. The BOM presented on page 15 provides a suggestion for the above mentioned power module. It is strongly recommended to customize the demo board to fit the application requirements for the power module that has been chosen. Suggestions on passive sizing are also available in DT04-4 at http://www.irf.com.
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IRMD22381Q BOARD CONNECTORS
P1 J1 P2 P3
Figure 1: TOP image of board
Connection with the system controller
On board there is a 40 pins connector for the control signals. The driver board uses 26 pins. The remaining pins are for the sensing board (IRCS2277S) that can be connected on top of IRMD22381Q board. Table 1: 40-pin connector J1
HINU/N FAULT/N 1 5
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40
2 4 6 8 12
LINU 5V SD BRIN/N HINV/N
LINV VSS VSS - RTRT+ LINW VFHU VFHW VFLV VCC VCC
13 17 19 21 25 29 31 33 37 39
18 20 24 26 30 32 34 38 40
VSS VSS HINW/N DCF VFHV VFLU VFLW VCC VCC
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IRMD22381Q
Input logical signals HINU/N, LINU, HINV/N, LINV, HINW/N, LINW, BRIN/N, SD
These logic inputs are 5V and 3.3 V compatible CMOS I/O ports. The logic signals ending with "/N" are active low. The board is populated with pull-up and pull-down resistors (to 5V supply) in order to keep inputs tied to supplies when controller is still inactive. HINx/N turns on the high side IGBT while LINx the low side. When both HINx/N and LINx of the same phase are active at the same time an internal anti-shot trough circuit turns off the output drivers.
FAULT logic signal
This is an output, open drain, logic signal. The logic signal is active low, tied to connector VCC with a 1k pull-up resistor. It reports the power module fault (IGBT desaturation detection, latched signal) or the VCC undervoltage (unlatched). On board a red LED (DL2) indicates when the signal is active; Figure 2a shows the connection.
DCF
Dc plus feedback voltage (DCF pin) is connected to a resistor divider tied from DC+ to VSS (DC-) and clamped by a 5V zener. At DC+= 330V, DCF1.4V.
RT+ and RTRT+ and RT-, thermistor output, are connected to the corresponding RT+, RT- pins of the power module. Note: RT- is starred to Vss at pin 19 of the J1 connector in the IRMD22381Q PCB.
VFHx and VFLx
Voltage feedback outputs from IRMD22381Q Note: further information about IR22381Q I/Os are described in details in IR22381Q datasheet.
VCC supply pin
This is the supply pin for all the devices. On board a green LED (DL1) indicates the supply power on; Figure 2b shows the connection.
5V 1k VCC 3.3k
Red
FAULT (a) VSS (b)
Green
Figure 2: LED connection
VSS ground pin (GND)
The board ground is connected to the power module DC- pin. The VSS pin of the connector and the devices ground pin are star-connected to the DC- pin. DC- star connection has been chosen to reduce the noise coupled from the floating signals.
5V
5V input supply for FAULT, VFx and inputs pull-ups.
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IRMD22381Q
Connecting the current sensors
P1, P2 and P3 are connected with the optional shunt resistors placed on the phase output nodes. CONNECTOR P1 SHU+ (motor side) SHU(power module side) U 1
1
2 3
2 3
CONNECTOR P2 SHV+ 1 (motor side) SHV2 (power module side) V 3
1 2 3
CONNECTOR P3 SHW+ 1 (motor side) SHW2 (power module side) W 3
1 2 3
Table 2: P1, P2 and P3 connectors for Kelvin contacts to shunt signals SHU, SHV and SHW are sense pins connected to the shunt resistors terminals.
High power signal connector
There connectors dedicated to each power signal (DC+, DC-, OUT+BRIDGE, OUT-BRIDGE, U, V, W). Each single connector has 25 Ampere of maximum nominal dc current. DCbus traces are both on top and on other internal layers of the PC board in order to reduce power dissipation. Connectors, DC-bus, phase and ground wires can be soldered directly on board using the corresponding pads located under the power connectors (to be removed).
Connecting the power module
The board is fully compatible with the ECONO2-PIM power module. The following table shows the module pin-out. CONNECTION POINTS BETWEEN BOARD AND MODULE 1 2 3 4 5 6 7 8 U bridge V bridge W bridge Phase U Phase V Phase W BRAKE - Brake IGBT drain output RT+ - thermistor positive pin
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IRMD22381Q
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 RT- - thermistor negative pin DC-SENSE phase U, V, W - low side IGBT emitter VGLW - phase W - low side IGBT gate VGLV - phase V - low side IGBT gate VGLU - phase U - low side IGBT gate VGBR - brake IGBT gate VEHW - phase W - high side IGBT emitter VGHW - phase W - high side IGBT gate VEHV - phase V - high side IGBT emitter VGHV - phase V - high side IGBT gate VEHU - phase U - high side IGBT emitter VGHU - phase U - high side IGBT gate OUT+BRIDGE - input rectifier positive output DC+ OUT-BRIDGE - input rectifier negative output DC- (GND) Table 3: High power module connection
Test Points
Test points on board provide signals that are not available at the connectors. See the following table:
ONE FOR EACH CHANNEL (CH1 U, CH2 V, CH3 W)
VB1,2,3 VS1,2,3 DSH1,2,3 DSL1,2,3 FAULT DSB BR VCC GND COM High side floating supply voltage High side floating supply offset voltage High side desat input voltage Low side desat input voltage OTHER Fault and Shut Down (or-wired) Brake desat input voltage Brake IGBT gate Low side and logic fixed supply voltage Device VSS DC-SENSE - common low side emitter voltage Table 4: Test points
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IRMD22381Q TEST BENCH CONNECTION
IRMD22381Q does NOT provide opto isolation. The following picture shows the recommended connections for board evaluation. Bold lines are equipotential (DC-=Vss=gnd).
Low Voltage supply
Oscilloscope
High Voltage supply
VCC Vdd
VSS gnd
DC-
DC+
Controller board
U V W
Flat cable or direct connection (preferred) via female connector, to provide signals and supply (Vcc=15V typ)
Figure 3: Test bench connection
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IRMD22381Q OPERATING DESCRIPTION
Normal operating mode
In the normal operating mode when HIN/N or LIN is active the high or low side IGBT turns on respectively. Turn on and turn off propagation delays and the propagation delay matching are specified in the IR22381Q datasheet. Devices introduce also the deadtime which is programmable (see product datasheet for details).
Fault management
The IR22381Q is able to detect the excessive current increase by monitoring the IGBT desaturation. The fault management procedure starts when one of the drivers senses the IGBT desaturation. The procedure is totally managed by an integrated FAULT LOGIC block without the controller assistance.
Multilevel board solution
With the optional shunt resistor the IRMD22381Q driver board can be connected with the IRCS2277S current sensing board through J1 and P1, P2, and P3 connectors. More information is available in IRCS2277S demo board data sheet.
Precharge of the bootstrapped sections
High voltage gate driver outputs are supplied by bootstrap topology technique. It's recommended to precharge the bootstrap supplies before starting to drive the motor with the preferred driving scheme.
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IRMD22381Q
BOARD CUSTOMIZATION
This demo board is meant to be flexible for self-customization. Place for many spare components allow verifying functionality of the gate driver under different external configurations. This section will go through the possible customizations of the board.
Bootstrap circuit
The high side floating supply (VBS) is provided by a bootstrap capacitor. Figure 4 shows the circuit on board.
DC+
R boot* D boot
VCC
VB
C boot* + C boot**
VGH
15V
C VCC
IR22381Q (1 leg)
R boot**
VEH
VS
phase
VSS
VGL VEL
Figure 4: Bootstrap circuit The following table shows the names of these components on board. U CVCC Cboot* Cboot** Rboot* Rboot** C004 C101 C104 R101 R106 V C004 C201 C204 R201 R206 W C004 C301 C304 R301 R306
Gate resistances
The following table shows the names of gate resistances on board. U high side gate to HOP R103 V R203 W R303
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IRMD22381Q
high side gate to HOQ high side gate to HON low side gate to LOP low side gate to LOQ low side gate to LON brake gate to BR R104 R105 R108 R109 R110 R408 R204 R205 R208 R209 R210 R304 R305 R308 R309 R310
OTHER EXTRA COMPONENTS
These components are provided to make IRMD22381Q board as customizable as possible. In many cases the use of the extra components is not necessary.
Desat circuit
The IR22381Q is able to detect the IGBT desaturation. To reject the noise on the desat pins the IR22381Q have an internal filter of 1sec. If this is not enough an RC filter has been placed on board (see figure 8, RDSH, CDSH and RDSL, CDSL).
High side desat diode
DC+
VCC
VB
BIAS
DSH 15V
C VCC
VGH VEH
IR22381Q (1 leg)
C DSH
VS
Vcc Low side desat diode
phase
VSS
DSL
C DSL
VGL VEL
COM
Figure 5: Desat external filter External C filter (R is provided internally~100Kohm) delays desaturation detection, that causes a delay in turning the IGBT off. Consider this delay when sizing the soft-shut-down resistors. The following table shows the names of these components on board. U CDSH CDSL CDSB C102 C103 C403 V C202 C203 W C302 C303
BIAS
R DSL
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IRMD22381Q
Clamping Diode for Vs below ground
This solution preserves the device when the VS pin goes below ground out of the device absolute maximum ratings. The VS voltage is clamped to the maximum value allowed by a zener diode.
DC+
R boot* D boot
VCC
VB
C boot* + C boot**
VGH
15V
C VCC
IR22381Q (1 leg)
R boot**
VEH
VS
phase
VSS
Clamping structure with zener diode
VGL VEL
Figure 6: -Vs clamp The following table shows the names of these components on board. U DIODE ZENER D104 Z102 V D204 Z202 W D304 Z302
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IRMD22381Q
RC filter on COM pin
An RC filter (RCOM, CCOM) is provided to preserve the IC device from low side IGBT emitter undervoltage spikes.
Vcc
CCOM RGOFF
ON
CVcc
Vss
COM
GATE DRIVER
RCOM
Figure 7: COM below ground protection The following table shows the names of these components on board. U, V, W CCOM RCOM C101 R006
Fast diode between gate and supply pin
On all low and high side drivers a fast diode is provided to clamp the gate coming over the VCC or VB supply pins and to recover the current coming from the collector node through the gate-collector capacitance.
DC+
DG
DH
VOUT
RONp DPn
VCC
RGATE VG VE QL
Figure 8: Collector-Gate current protection The following table shows the names of these components on board. U V (high side) DG (low side) DG (brake) DG D103 D105 D405 D203 D205
W D303 D305
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IRMD22381Q
Zener diode to preserve the IGBT gate
To avoid a VGE increasing over the absolute maximum rating a zener diode is connected between gate and emitter pins on all the IGBTs.
DC+
GATE DRIVER
VCC
low voltage supply
high side driver
Rboot
VS
VOUT
LOAD
VSS
low side driver
RCOM
QL
DL
COM
GND
Figure 9: Zener clamp for IGBT gate The following table shows the names of these components on board. U (high side) ZENER (low side) ZENER (brake) ZENER Z101 Z103 Z403 V Z201 Z203 W Z301 Z303
Optional output shunt resistor
Two type of output shunt resistor, for current sensor, are possible see the following table: U TO220 or OARS-1 R111 R111A R111B // V R211 R211A R211B // W R311 R311A R311B //
The OARS-1 type (A and B) are connected in parallel.
Resistor on vcc
Provided to decouple VCC from supply line. U, V, W Vcc decoupling R001
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IRMD22381Q BILL OF MATERIAL
The hereafter provided BOMs represent a suggestion based on the IGBT characteristics shown below.
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IRMD22381Q
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IRMD22381Q
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IRMD22381Q
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IRMD22381Q LAYOUT
TOP SILK
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IRMD22381Q
TOP LAYER
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IRMD22381Q
INT1 LAYER
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IRMD22381Q
INT2 LAYER
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IRMD22381Q
BOT LAYER
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IRMD22381Q BOT SILK
WORLD HEADQUARTERS: 233 Kansas Street, El Segundo, California 90245 Tel: (310) 252-7105 http://www.irf.com/ Data and specifications subject to change without notice. 5/26/2005
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