IRMD26310DJ

24 July 2008 Data Sheet No. PD60359 IRMD26310DJ 3 PHASE GATE DRIVER IC REFERENCE DESIGN KIT Product Summary AC input Voltage (typ.) Continuous motor current dV/dt Bus over voltage protection (typ.) Continuous output power 220 V rms 3 A rms 5 kV/µs 386 V 400 W IRS26310DJ GATE DRIVER IC FEATURES • • • • • • • • • • • • • • • • • Drives up to six IGBT/MOSFET power devices Gate drive supplies up to 20 V per channel Integrated bootstrap functionality DC bus sensing with Over Voltage protection Over-current protection Over-temperature shutdown input Advanced input filter Integrated deadtime protection Shoot-through (cross-conduction) protection Under voltage lockout for VCC & VBS Enable/disable input and fault reporting Adjustable fault clear timing Separate logic and power grounds 3.3 V input logic compatible Tolerant to negative transient voltage Designed for use with bootstrap power supplies Matched propagation delays for all channels REFERENCE DESIGN FEATURES • • Complete 3-phase ac motor drive system to showcase IRS26310DJ gate driver IC operation No extra hardware needed for PWM signal generation; Option to incorporate external PWM signals to drive IRS26310DJ if desired GUI software for running Induction Motor in open loop Volts-per-Hertz mode of operation Discrete IGBT power stage for maximum flexibility o o IGBT’s rated for 10A @100 C o Short circuit rating 10 µs o TO220 Full-pak package Conveniently located Test points for IRS26310DJ signal monitoring • • • Overview The IRMD26310DJ is a reference design kit for the IRS26310DJ three phase gate driver IC with integrated bootstrap functionality and DC bus overvoltage protection. The design kit includes a complete drive system board with an input rectifier, control power supplies, digital motor control IC and power inverter. Safety features include protections against motor line-to-line, line-to-DC Bus(-) short situations & DC bus overvoltage conditions. The power stage features the IRS26310DJ gate driver and six discrete IGBT power switches allowing for easy customization. The included PC based GUI software allows the user to drive an Induction Motor in open-loop Volts-per-Hertz mode of operation using the on-board digital control IC. The motor speed and system parameters such as PWM frequency and deadtime can be modified using the GUI. Alternately, the IRS26310DJ gate drive input PWM signals can be supplied externally by patching in signals through an on-board connector. Rev 1.3 © 2008 International Rectifier IRMD26310DJ Table of Contents Safety Precautions…………………………………………………………………………………………………….4 IRMD26310DJ Hardware Description………………………………………………………………………............6 Top Level Description………………………………………………………………………………………………6 IRS26310DJ Gate Driver IC……………………………………………………………...………………………..7 Bootstrap Supply……………………………………………………………………………………………………8 Gate Drive Resistors……………………………………………………………………………………………….8 IRMD26310DJ Protection Features……………………………………………………………………………...9 IRMD26310DJ Fault Reporting…………………………………………………………………………………...9 Automatic Reset after ITRIP Fault………………………………………………………………………………..9 IRMD26310 Enable Function…………………………………………………………………………………….10 PWM input to IRS26310DJ & Connection of an external system controller………………………………..10 Test Points for Investigation……………………………………………………………………………………...11 IRMD26310DJ Operating Instructions……………………………………………………………………………..12 Software Installation……………………………………………………………………………………………….12 Test Bench Connection…………………………………………………………………………………………...12 Powering the Board………………………………………………………………………………………………..13 Running the Software GUI………………………………………………………………………………………..14 Software GUI Fault Handling Instructions……………………………………………………………………….17 How to Trigger IRS26310DJ DC Bus Overvoltage Protection………………………………………………..18 IRMD26310DJ Software GUI Reference Guide…………………………………………………...……………...19 Motor Parameters………………………………………………………………………………………………….19 Inverter Parameters………………………………………………………………………………………………..19 System Status………………………………………………………………………………………………………19 Control………………………………………………………………………………………………………………19 Monitors……………………………………………………………………………………………………………..20 Speed Control………………………………………………………………………………………………………20 IRMD26310DJ Circuit Schematics………………………………………………………………………...………..21 IRMD26310DJ Bill of Materials..…………………………………………………………………...………………..25 IRMD26310DJ Specifications…………………………………………………………………………………….....28 www.irf.com © 2008 International Rectifier 2 IRMD26310DJ List of Figures Figure1: IRMD26310 system block diagram…………………………………………………………………………6 Figure 2: Picture of IRMD26310 reference design…………………………………………………………………..7 Figure 3: IRS26310 application diagram……………………………………………………………………………...7 Figure 4: Bootstrap circuit……………………………………………………………………………………………...8 Figure 5: Gate circuit……………………………………………………………………………………………………8 Figure 6: Protection circuits, fault reporting & automatic reset after ITRIP fault………………………………..10 Figure 7: 20 Pin connector, P1……………………………………………………………………………………….10 Figure 8: Test bench connection……………………………………………………………………………………..12 Figure 9: Board connections………………………………………………………………………………………….13 Figure 10: 8 pin connector, J1………………………………………………………………………………………..13 Figure 11: Location of diagnostic LEDs in IRMD26310DJ………………………………………………………...14 Figure 12: Software GUI before establishing communication between IRMD26310DJ and PC………………14 Figure 13: COM port selection………………………………………………………………………………………..15 Figure 14: Software GUI after establishing communication between IRMD26310DJ and PC………………...15 Figure 15: Software GUI after successful configuration of IRMD26310DJ……………………………………...16 Figure 16: Software GUI while running the motor using IRMD26310DJ…………………………………………17 Figure 17: Software GUI during 2 different fault situations………………………………………………………..17 Figure 18: IRS26310DJ DC bus overvoltage protection…………………………………………………………..18 Figure 19: Zero-vector insertion during IRS26310 DC bus overvoltage protection………………………........18 Figure 20: IRMD26310DJ power stage circuit schematic…………………………………………..……………..21 Figure 21: IRMD26310DJ Digital Control & Communications Circuit Schematic………………….…………...22 Figure 22: IRMD26310DJ RS-232 Drivers & Receivers Circuit Schematic……………………..……………....23 Figure 23: IRMD26310DJ DC-DC Converter Low Voltage Power Supply Circuit Schematic..………………..24 List of Tables Table 1: Gate drive circuit components………………………………………………………………………………8 Table 2: List of test points…………………………………………………………………………………………….11 Table 3: List of faults issued by GUI…………………………………………………………………………………20 Table 4: IRMD26310 electrical specifications………………………………………………………………………28 www.irf.com © 2008 International Rectifier 3 IRMD26310DJ Safety Precautions In addition to the precautions listed throughout this manual, please read and understand the following statements regarding hazards associated with development system. ATTENTION: The ground potential of the IRMD26310DJ system is biased to a negative DC bus voltage potential. When measuring voltage waveform by oscilloscope, the scope ground needs to be isolated. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ! ! ! ! ATTENTION: The IRMD26310DJ system contains dc bus capacitors, which take time to discharge after removal of main supply. Before working on drive system, wait three minutes for capacitors to discharge to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: Only personnel familiar with the drive and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: The surface temperatures of the drive may become hot, which may cause injury. www.irf.com © 2008 International Rectifier 4 IRMD26310DJ ! ATTENTION: The IRMD26310DJ system contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference applicable ESD protection handbook and guideline. ! ATTENTION: An incorrectly applied or installed drive can result in component damage or reduction in product life. Wiring or application errors such as undersizing the motor, supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result in system malfunction. ! ! ATTENTION: Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Wait three minutes after removing power to discharge the bus voltage. Do not attempt to service the drive until bus voltage has discharged to zero. Failure to do so may result in bodily injury or death. ATTENTION: Do not connect power factor correction capacitors to drive output terminals U, V, and W. Failure to do so may result in equipment damage or bodily injury. Debris When Unpacking IRMCS3041 system is shipped with packing materials that need to be removed prior to installation. ATTENTION: Failure to remove all debris and packing materials which are unnecessary for system installation may result in overheating or abnormal operating condition. ! www.irf.com © 2008 International Rectifier 5 IRMD26310DJ IRMD26310DJ - Hardware Description The IRMD26310DJ reference design kit supports the evaluation of the IRS26310DJ which is a high voltage power MOSFET and IGBT driver with integrated DC Bus overvoltage protection. The reference design is a full-function unit operating out of 220VAC input. An onboard digital controller IC enables driving an Induction Motor in openloop Volts-per-Hertz mode. The included GUI software allows modification of system parameters in order to drive an induction motor in open-loop Volts-per-Hertz mode and study the IRS26310DJ high voltage gate driver IC by changing parameters such as PWM frequency and deadtime. In addition to DC Bus overvoltage protection offered by IRS26310DJ, the reference design is equipped with protection against motor line-to-line and line-to-DC Bus(-) short by way of IRS26310DJ ITRIP function and also a GUI software controlled motor current limit. The board includes multiple test points to facilitate monitoring IRS26310DJ input and output signal waveforms and examining its various features. Top Level Description The IRMD26310DJ reference design is composed of the following key blocks: • The Input Stage includes an EMI filter, 8A bridge rectifier and dc bus capacitor rated for 400W continuous operation. It is noted that IRMD26310DJ does not feature a current limiting fuse. o • The Power Inverter uses 6 x IRGIB10K60D1 IGBT power switches mounted on a 1.9 C/W heatsink. The IGBTs can be replaced with user preferred power devices but user may need to replace components such as bridge rectifier & dc bus current shunt to match the device ratings. • The IGBTs in the power inverter stage are driven by the IRS26310DJ Gate Driver and associated circuitry involving bootstrap capacitors, gate drive timing resistors, and fault diagnostic elements. • The Control Circuitry for driving the motor is based on the IRMCF341 digital control IC. The IRMCF341 control IC has been configured to run an induction motor in the open-loop Volts-per-Hertz mode. The control IC generates the PWM signals for IRS26310DJ gate driver. The user also has the option to drive the IRS26310DJ externally by disconnecting the jumpers on connector P1 and bridging in external connections. The digital IC communicates with a PC over an isolated serial link and the included GUI software allows the user to set the motor speed and modify common inverter parameters such as switching frequency and deadtime. • An on-board DC-DC Converter low voltage power supply derives the 15V, 3.3V & 1.8V rails from the main dc bus. For more information regarding the other blocks of the reference design, please refer to the detailed schematics. Figure 1: IRMD26310DJ System Block Diagram www.irf.com © 2008 International Rectifier 6 IRMD26310DJ DC-DC Converter Input Input Stage Control Circuitry Power Inverter PC Connector Gate Driver Circuitry Connector for external PWM drive Figure 2: Picture of IRMD26310DJ Reference Design IRS26310DJ Gate Driver IC The IRS26310DJ IC integrates three independent half bridge drivers with shoot through protection and internal dead-time insertion. Proprietary HVIC technology enables ruggedized monolithic construction with logic inputs compatible with CMOS or LSTTL levels as low as 3.3 V. The output drivers feature a high pulse current buffer stage designed for minimum driver cross-conduction. Propagation delays are matched to simplify use in high frequency applications. The floating channel can be used to drive N-channel power MOSFETs or IGBTs in the high side configuration, which operates up to 600V. The IC is based on “Active High” input logic i.e. a logic HIGH input turns ON the corresponding output and vice versa. In addition to VSS pin, the IC features a COM pin to provide a dedicated, low impedance return path for the low side gate driver which also serves to shunt the highfrequency gate drive currents away from the current sense resistor thus preventing false trips. The IC provides DC bus capacitor protection by activating zero-vector motor braking whenever an overvoltage condition is sensed. This feature should only be used with motors that can withstand short-term short circuit of the motor windings. Other protection features offered by the IC include UVLO for VCC & VBS supplies and motor current trip along with integrated fault diagnostics are also offered in IRS26310DJ. An open-drain FAULT signal is provided to indicate that an over-current or a VCC under-voltage shutdown has occurred. An enable function integrated into the FAULT/ pin allowing the user to terminate all six outputs simultaneously. Figure 3: IRS26310DJ Application Diagram www.irf.com © 2008 International Rectifier 7 Power Connector IRMD26310DJ Bootstrap Supply The floating high side driver supplies are generated by a bootstrap circuit as shown in Figure 4. The IC turns on the internal ‘bootFET’ when the low side transistor is on to charge up the bootstrap capacitor (Cboot). The ‘bootFET’ eliminates the requirement for an external boot diode Dboot as is the case for previous generation gate drivers. An application note AN-1123 (http://www.irf.com/technical-info/appnotes/an-1123.pdf) describes the selection of the bootstrap capacitor and considerations when using the internal bootFET. In some cases, an external bootstrap circuit may be preferable. The IRMD26310DJ board also provides option for external bootstrap supply. This can be invoked by populating the bootstrap resistor, Rboot (R17) and bootstrap diodes (D6, D7 & D8). The bootstrap capacitors must be fully charged to avoid missing high side pulses due to under voltage lockout on the floating high side supply. The digital controller on the board pre-charges the capacitors by turning on the low side transistors for a short period before starting to run the motor. The charging current and time depends on the resistance of the internal bootFET or the external boot resistance. Typically, the pre-charge sequence charges the capacitors one at a time to avoid spurious over current trips since the charging current flows through the current sensing shunt. Figure 4: Bootstrap circuit Gate drive resistors The IRMD26310DJ board has gate resistor networks to allow fine tuning of the power switch turn on and turn off times. Figure shows the gate circuit schematic while Table 1 list the resistors used in the network for each power device. Figure 5: Gate circuit U V High side gate (HO turn-on/off) R61/R99/D9 R62/R101/D10 Low side gate (LO turn-on/off) R64/R119/D12 R65/R120/D13 Table 1: Gate drive circuit components www.irf.com W R63/R118/D11 R66/R121/D14 © 2008 International Rectifier 8 IRMD26310DJ IRMD26310DJ Protection Features Motor Overcurrent Protection Motor over-current protection is implemented using a dc link shunt resistor (R60) placed between power ground (COM pin) and logic ground (VSS pin) as shown in Figure 6. The ITRIP signal from the shunt has an input RC filter (R38, C37) to reject power inverter noise. The IRS26310D has a comparator that generates a shutdown signal when the ITRIP pin voltage exceeds the ITRIP threshold (VIT,TH+). An internal noise filter rejects pulses shorter than 400ns to avoid spurious trips due to diode reverse recovery current. The shutdown signal turns off all six outputs and pulls the FAULT / EN pin low. When the over-current condition is cleared, the fault remains latched until reset by the voltage on the RCIN. Under-voltage protection circuits The IC monitors the supply voltage on the VCC pin. It turns off all six outputs and pulls the FAULT / EN pin low when VCC falls below a minimum threshold (VCCUV-). This fault is not latched but is cleared once VCC goes above the positive going threshold (VCCUV+). The IC also features UVLO protection for all 3 VBS floating supplies; However, a VBS UVLO condition does not trigger fault reporting i.e. FAULT / EN pin is not pulled low. Under a VBS UVLO condition, only the corresponding gate driver output is terminated until the VBS UVLO condition is cleared. DC Bus over-voltage protection circuits The IRS26310D monitors the dc bus to prevent it charging to an unsafe voltage level during regenerative braking. The divider network R35, R36 and R37 drops the DC bus to a low voltage level and communicates to IRS26310D. A comparator and noise filter detects a bus over-voltage condition when the voltage on the DCBusSense pin goes above a maximum threshold (VDCBUSOV+). The default resistor divider configuration in IRMD26310DJ will trigger IRS26310DJ DC bus overvoltage protection feature at approximately 386V. When an over-voltage condition is sensed, it forces IRS26310DJ into zero vector mode, which turns on all low side transistors and turns off all high side transistors irrespective of the PWM input commands from digital control IC. IRS26310DJ then returns to normal operating mode when the voltage on the DCBusSense pin drops below a minimum threshold (VDCBUSOV). The dc bus over-voltage state is not reported on the FAULT / EN pin. For more information regarding how to trigger the DC bus overvoltage protection feature, please refer to “Operating Instructions” section. IRMD26310DJ Fault Reporting The FAULT / EN pin of the IC is used to communicate a fault situation to the digital control IC (DCIC). The FAULT / EN pin, which is normally pulled up to 3.3V using pull up resistor, is connected to the GATEKILL pin on the IRMCF341. When the IC detects a fault situation (either due to VCC UVLO or ITRIP) all gate driver outputs are shut-down and the FAULT / EN pin is pulled low and this triggers the GATEKILL function of IRMCF341 causing all PWM outputs of IRMCF341 to be shutdown. Fault reporting is performed only for the following: - Motor overcurrent (ITRIP) - VCC supply UVLO It is again noted that VBS UVLO & dc bus overvoltage situations do not trigger a fault situation. Automatic Reset after ITRIP Fault Automatic fault reset provided by the HVIC is based on the time constant (RCreset) of the passive network on the RCIN pin. An RC network (R39, C38) between the RCIN pin and VCC supply allows an automatic reset of the ITRIP fault. The capacitor on the RCIN pin is held low as long as the ITRIP comparator input exceeds the ITRIP voltage threshold. When the ITRIP fault condition clears, the capacitor is allowed to charge up. The ITRIP fault is reset when the capacitor voltage exceeds a minimum threshold (VRCIN,TH+). The RCIN auto-reset time can be calculated from the following equation:  Vcc t = R39 ⋅ C38 ln  V −V RCinTH +  cc     The reference design auto reset time is approximately 1.6ms for Vcc=15V, VRCinTH+=8V and R39=2MOhm, C38=1nF. The on resistance of the reset FET on the RCIN pin cannot be neglected so a relatively small capacitor should be used so that it becomes fully discharged before the fault is released. www.irf.com © 2008 International Rectifier 9 IRMD26310DJ IRMD26310 Enable Function The IC features an Enable function integrated into the FAULT / EN pin to provide enable/disable functionality. The IC functionality is enabled when EN pin is biased high. In the IRMD26310DJ reference design, the FAULT / EN pin is pulled up to 3.3V DC bus using resistor R28 potential to always enable operation. Figure 6: Protection circuits, Fault Reporting & Automatic Reset after ITRIP fault PWM input to IRS26310DJ & Connection of an external system controller IRMD26310DJ is configured by default to use the PWM signals from the on-board IRMCF341 controller for the IRS26310DJ HVIC. The default configuration connects the IRMCF341 digital control IC to the IRS26310DJ by shorting pins 5-6, 7-8, 9-10, 11-12, 13-14, 15-16, 17-18 on connector P1 shown in Figure 7. Since the IRS26310DJ is based on Active High logic, the PWM inputs to the HVIC in IRMD26310DJ are connected to GND using pull-down resistors (R26 to R32). An external controller can easily be invoked for driving the IRS26310J by removing the shorting connections on the 20 pins DIL connector P1 and connecting the external PWM signals to the odd numbered pins on P1. It is reiterated that the correct PWM inputs that is appropriate for the “Active High” logic of IRS26310DJ must be maintained. Figure 7: 20-pin connector P1 www.irf.com © 2008 International Rectifier 10 IRMD26310DJ Test Points for Investigation The reference design is provided with ample test points to probe the different pins of the gate driver IC and inverter circuit. The following table provides a summary of the most useful test-points around the IRS26310DJ HVIC and their associated functionality. Test Point # Test Point Name Remark TP28, 29, 30 TP37, 38 & 39 TP9, 10, 11 TP31, 32, 33 TP7, 8, 9 TP34, 35, 36 TP24 TP22 TP2 TP4 TP14, 15, 25, 26, 27 TP103 U, V, W VB3, VB2, VB1 UH, VH, WH UG, VG & WG UL, VL, WL UG/, VG/, WG/ COM GK IFB DCP GND VCC Motor Phase nodes (also negative terminals of bootstrap supply voltage) Boot-strap supply voltage positive terminal PWM input to high-side channels of HVIC (HIN1, HIN2 & HIN3) Gate of high-side IGBTs PWM input to low-side channels of HVIC (LIN1, LIN2 & LIN3) Gate of low-side IGBTs Common emitter of low-side IGBTs (also Positive terminal of current shunt resistor) FAULT / EN pin of IRS26310D (also Input to IRMCF341 GATEKILL pin) Motor current feedback DC Bus Logic ground of IRS26310D (VSS pin) & DC Bus return VCC pin of IRS26310D Table 2: List of Test Points www.irf.com © 2008 International Rectifier 11 IRMD26310DJ IRMD26310DJ – Operating Instructions The following hardware is supplied with the IRMD26310DJ reference design kit • IRMD26310DJ board with heat sink • GUI Software CD-ROM • PC USB-serial cable & driver CD-ROM Visually inspect IRMD26310DJ board to check for loose wiring, loose or damaged components or other abnormalities before proceeding. STEP 1: Software Installation The reference design kit is supplied with IRMD26310 GUI v1.0 software intended to support the evaluation of IRS26310DJ HVIC. The on board digital control IC (IRMCF341) generates the inverter PWM signals and can run a three phase induction motor using open loop V/F or Volts-per-Hertz control. This software is the GUI that allows the specification of the motor, inverter and system parameters. The software tool is distributed on a CD-ROM. Load the CD into the CD-ROM drive on a PC and if installation does not start double-click on the .exe installation file. The automated procedure installs all necessary software and documentation on the PC. The default location for the installation is “C:\Program Files\IR\IRMD26310DJ”. STEP 2: Test Bench Connection 1. Connect the ac power cables to Earth (E), line (L) and neutral (N) terminals of J1 connector. Prepare a power contactor switch rated at 250V/10A in series with AC power cables if necessary. ATTENTION: Turn off or unplug the power before making any connections to board. All circuits on board must be considered as ‘live’ with respect to the safety earth so please use extreme caution when making connections to circuit board. It is recommended to isolate the oscilloscope ground when making circuit waveform measurements. ! 2. Connect the motor windings to the U/V/W terminals of connector J1. If needed, connect the motor frame to the Safety Earth connection available on the E terminal of connector J1. NOTE: GND terminal of connector J1 is NOT to be used for the purpose of safety grounding. 3. Connect the RS-232 cable between the DB-9 connector J6 on IRMD26310DJ board and an available COM port (USB port) on your PC. The RS-232 serial connector is galvanically isolated from the circuit board ground so the user can safely connect a PC to the board. Figure 8: Test bench connection www.irf.com © 2008 International Rectifier 12 IRMD26310DJ To PC Phase U Phase V Phase W DC Bus GND Neutral Line Earth Earth To Motor To AC Input Figure 9: Board connections E Safety Earth (connected to the heatsink) L AC line input N AC neutral input GND DC bus ground DCP Positive DC bus U motor U phase V motor V phase W motor W phase Figure 10: 8-pin connector J1 ! ATTENTION: The GND terminal of connector J1, called DC Bus Ground, is biased to the negative DC bus voltage potential of IRMD26310DJ, which connects to the ac power line input via the input rectifier. The GND terminal is NOT to be confused with safety ground of the system. Instead, the E terminal of connector J1, called Safety Earth, is to be used for purpose of safety grounding. Failure to follow these instructions can result in personal injury or death. STEP 3: Powering the Board Connect the power cables to 220VAC mains and turn-on the power switch. There are 2 on-board LEDs for diagnostic purposes as shown in Fig.11. 1. Check if LED2 is lit in red after you apply AC power. LED2 is connected to the dc bus and indicates that power is connected to the board and the on-board switching mode power supply is active. NOTE: Never attempt to service the board or engage/disengage any connections when LED2 is lit since it indicates the presence of high-voltages on the board. 2. Check if LED1 is a slowly flashing green. LED1 is driven by the digital control IC IRMCF341 controller. It is lit red when a fault is detected and slowly flashes green when IRMCF341 is in proper operational status. If LED1 is lit red after powering the board then it indicates one of the following: i. Under-voltage fault: This occurs if rectified DC bus voltage is less than 120V; Check DC Bus & AC input voltage levels and ensure DC bus is greater than 120V. Then proceed to Step 4. LED1 will be a flashing green once Step 4 is completed. ii. Over-voltage fault: This occurs if rectified DC bus voltage is greater than 360V; Check DC Bus & AC input voltage levels and ensure that DC bus is less than 360V. Then proceed to Step 4. LED1 will be a flashing green once Step 4 is completed. iii. Reference Design Configuration Error: Contact IR Support. www.irf.com © 2008 International Rectifier 13 IRMD26310DJ LED1 LED1 LED2 Figure 11: Location of diagnostic LEDs in IRMD26310DJ STEP 4: Running the Software GUI Step 4a: Start the GUI software program on PC Start the GUI Software by clicking the desktop icon or double-clicking .exe file. Figure 12: Software GUI before establishing communication between PC & IRMD26310DJ Note the following: www.irf.com © 2008 International Rectifier 14 IRMD26310DJ All 3 icons in System Status section of GUI in the top-right corner of the GUI (Connection Status, Fault Status & Configuration Status) are yellow in color. At the bottom of the GUI the messages “No COM Port Set” & “Disconnected” are displayed All buttons in the Controls section of GUI are disabled Step 4b: Selecting the COM port (RS-232) The software on the PC communicates with the digital control IC on-board using a COM port. It is necessary to select the COM port to which the USB cable is connected to run the GUI software. COM port can be selected by clicking on “COM Settings” at the bottom-left of the GUI window and selecting one of the options. Figure 13: COM port selection W hen the correct COM port has been selected and communication is successfully established, - the “Connection status” & “Fault status” icons in the System Status section of the GUI should change colors from yellow to green - the Monitor section icons should change color from yellow to green and provide real time information regarding the item being monitored i.e. DC Bus Voltage & Output current - the “Fault Clear” & “Configure” buttons in Controls section are enabled and - the messages “COM# Set” (where # is the appropriate COM port number) and “COM Port UP” are displayed at the bottom. Figure 14: Software GUI after establishing communication between PC & IRMD26310DJ www.irf.com © 2008 International Rectifier 15 IRMD26310DJ Step 4c: Configuring the Hardware After the selection of inverter and motor parameters on the GUI click on the ‘Configure’ button to load them to the digital control IC on the IRMD26310DJ board. This step is absolutely necessary before the motor can be started. Please refer to “Software GUI Reference Guide” section for more information about GUI parameters and the associated system implications. Upon successful configuration, the - the “configuration status” icon in the System Status section of the GUI should change colors from yellow to green - the “Start” button in Controls section is enabled NOTE: Remember to press the configure button every time after a change is made to any GUI parameter. NOTE: The DC bus voltage must remain constant after pressing the configure button, otherwise the control algorithm will not operate as expected. Remember to press the configure button after every time the DC bus level is altered. Figure 15: Software GUI after successful configuration of IRMD26310DJ www.irf.com © 2008 International Rectifier 16 IRMD26310DJ Step 4d: Starting, Running & Stopping the Motor - To start the motor, press the “Start” button in the Controls section. The motor will start and accelerate to the specified rotation speed. Further, the “Start” button in the Controls section of the GUI will toggle into a “Stop” button Figure 16: Software GUI while running the motor using IRMD26310DJ - W hile running, the motor speed can be changed real-time by using the slide bar to set the new speed. To stop the motor, simply press the “Stop” button. The motor will coast to a full stop. Further, the “Stop” button will toggle back to “Start”. Software GUI Fault Handling Instructions A fault situation may be triggered either by the software GUI or hardware (digital control IC). Please refer to the “Software GUI Reference Guide” section for more information about the fault conditions that can be encountered during operation. In both cases, when a fault is encountered during motor operation, the GUI immediately stops the motor. Further, - the “Fault Status” icon in System Status section changes to red; In addition, if the fault condition is related to any of the Monitors, then the appropriate Monitor icon also changes color to red - the “Start” button in Controls Section is disabled - the fault condition is displayed at the bottom of the GUI Please refer to “Software GUI Reference Guide” section for a complete list of faults that may be encountered during operation. Figure 17: Software GUI during 2 different fault situations To clear the fault and restart motor, the following actions are performed in the specified sequence - press the “Fault Clear“ button in Controls Section; the “Fault Status” icon & the respective system monitor icon in System Status section then change from red to green - Reconfigure the motor as outlined in Step 4b - Proceed to running the motor as outlined in Step 4c www.irf.com © 2008 International Rectifier 17 IRMD26310DJ How to Trigger IRS26310DJ DC Bus Overvoltage Protection The IRS26310D gate driver IC monitors the DC bus voltage to prevent it from charging to an unsafe voltage level during regenerative braking when used to drive permanent magnet motors. The DC bus voltage is scaled down using a resistor divider and communicated to the DCBusSense pin. When the voltage on the DCBusSense pin goes above a maximum threshold (VDCBUSOV+) an over-voltage condition is sensed and it forces IRS26310DJ into zero vector mode. In this mode the driver turns-on all low side transistors and turnsoff all high side transistors irrespective of the PWM input commands from digital control IC. The divider network R35, R36 and R37 in IRMD26310DJ sets DC bus overvoltage protection level to 386V. Figure 18: IRS26310 DC Bus Overvoltage Protection Feature Since IRMD26310DJ will be used to drive an Induction motor, which does not engage regenerative braking like a permanent magnet motor, it is not straightforward to trigger the DC bus overvoltage protection of the driver IC. However, the following suggestions are provided i. The Decel Rate parameter in software GUI is used to define the ramp-down characteristic of the induction motor during halting. A smaller value halts the motor more abruptly. By engaging an abrupt stop of the induction motor when running at a high speed under loaded condition, it is possible to create a DC bus voltage overshoot during motor stop. Zero vector insertion is triggered when the overshoot exceeds 386V. For more information regarding the Decel Rate parameter please refer to “Software GUI Reference Guide” section. Further, by changing resistor R37, it is also possible to decrease the DC bus overvoltage level at which the protection is triggered to suit other test conditions such as AC input voltage level, motor speed, load-under-test etc. For example, in Fig.19 where zero-vector insertion is activated during motor stop, the reference design was modified to trigger DC Bus overvoltage protection feature at 275V. DC Bus Voltage Motor Current LO1 LO1 Zero-vector insertion & LO turn-on ZOOM-IN ii. Figure 19: Zero vector insertion during IRS26310DJ DC Bus overvoltage protection The DC bus overvoltage feature can also be engaged in a “static” test (motor not running) in order to verify the IC functionality. To do this the AC input voltage level can simply be increased high enough to result in a rectified DC bus voltage greater than 386V; However, in this method, running the motor will not be possible since software GUI will trigger a “DC Bus Voltage Level fault”. © 2008 International Rectifier www.irf.com 18 IRMD26310DJ IRMD26310DJ – Software GUI Reference Guide M otor parameters • • • • • • Number of poles – The number of poles defines the ratio of the electrical to mechanical frequency in the induction motor (# of poles = Electrical Frequency/Mechanical Frequency). This is selected from the drop down menu in the GUI. Only even number values are listed in the drop down menu since the motor poles come in pairs. M ax speed – This is the maximum speed that the motor can run. The motor speed cannot be set faster than this value. This is entered in revolutions per minute (RPM). This parameter can be obtained from the motor nameplate. M in speed – This is the minimum speed that the motor can run. The speed cannot be set lower than this value. This is entered in revolutions per minute (RPM). Current Limit – This is the maximum RMS current (phase current in the motor) that the system will allow in the motor before the GUI triggers a fault and stops the motor. This is entered in amperes (A). This parameter can be obtained from the motor nameplate. Volts – This is the rated RMS voltage (L-L) of the induction motor. This parameter is the voltage used in the V/Hz control algorithm. This is entered in Volts (V). This parameter can be obtained from the motor nameplate. NOTE: W hen the configure button is pressed this value is sampled along with the current DC bus. The DC bus must remain constant after pressing the configure button, otherwise the control algorithm will not operate as expected. Base Speed – This is the rated electrical frequency for running the induction motor. This parameter is the Hertz value used in the V/Hz control algorithm. This is entered in Hz. This parameter can be obtained from the motor nameplate. Inverter parameters • Carrier frequency - User selectable input of PWM frequency of inverter. This is entered in KHz in the range from 5kHz to 35khz. • Dead time – The dead time that will be present between switching high and low side IGBTs. This is entered in µs. Typically, deadtimes are less than 1usec. System Status • Connection status – Indicates if the connection between software and IRMCF341 is working and active. Green indicates successful connection, while yellow indicates lack of connection. Other System status icons also remain yellow when there is no connection. • Fault Status – Indicates if any faults are present in the system. Green indicates fault-free status while red indicates occurrence of a fault. The fault condition is displayed at the bottom of the GUI and the associated Monitor icon is also lit red, if applicable. Faults can be cleared by pressing the Fault Clear button. If the fault remains even after pressing the Fault Clear button then it indicates that the underlying fault condition is continuing to persist. Table 3 shows a list of all the faults that can be encountered. • Configure Status – Indicates if any parameters have been modified since the last configure. If this indicator is yellow, the configuration button should be pressed again prior running the motor. It is recommended to press the configuration button every time before starting and running the motor. Control • Fault clear – This button will clear all of the faults present in the system. If the fault remains even after pressing this button it indicates that the fault situation is continuing to persist. This button will be disabled when a PC-to-hardware connection is not present and when the motor is running. Shutdown power and restart GUI to resume operation. www.irf.com © 2008 International Rectifier 19 IRMD26310DJ • Configure - This button will configure the hardware with the parameters that have been selected in the GUI. This step is not done automatically. Remember to configure the hardware every time a parameter is altered or DC bus voltage level is changed. This button will be disabled when a PC-tohardware connection is not present and when the motor is running. Shut-down power and restart GUI to resume operation. Start/Stop – This toggle-type button starts and stops the motor. During motor-start, an acceleration control gradually ramps the motor speed to the value in “Requested Speed” field. Fault Type (source) Hardware Generated (by Digital IC) Explanation of Fault Fault Trip Level • Fault Name Overvoltage Fault Undervoltage Fault Hardware Generated (by Digital IC) Hardware Generated (by Digital IC) Hardware generated (by HVIC) Software Generated Software Generated DC Bus Voltage Level Fault Gatekill Fault Overcurrent Fault System Error Indicates DC bus over-voltage condition at system power-up (NOTE: this fault occurs only during power up, when GUI is still unconfigured) Indicates DC bus voltage under-voltage condition at system power-up (NOTE: this fault occurs only during power up, when GUI is still unconfigured) Indicates either a DC bus over-voltage or under-voltage condition (NOTE: this fault occurs after GUI has been configured) Indicates ITRIP fault or VCC UVLO fault occurring in IRS26310DJ; Gatekill fault is triggered by FAULT / EN pin of IRS26310D Indicates that motor current fault DC Bus Voltage > 360V DC Bus Voltage < 120V Indicates out-of-bounds errors, contact IR support Table 3: List of faults issued by software GUI DC Bus Voltage > 360V OR DC Bus Voltage < 120V VCC < 8.2V (Typ) AND/OR V(R60) > 14A (Typ) RMS Motor Current calculated by GUI > “Current Limit” - Monitors • DC bus voltage – The instantaneous voltage of the DC bus. The over-voltage fault is encountered if the DC bus increases beyond 360V. The under-voltage fault is encountered if DC bus is less than 120V. • Output current – The rms motor current calculated by software. It is dependent on the shunt resistor value defined on the system parameter. The over-current fault is encountered if the calculated value exceeds the “Current Limit” parameter. Speed Control • The START button in the GUI starts the motor and gradually ramps the motor speed to the specified value in “Requested Speed” field. In addition, the GUI has a slider to adjust the motor if it is already running. An acceleration control is included to gently accelerate to the requested speed and is not user definable. • Decel Rate - DecelRate parameter is used to define the ramp-down characteristic of the motor during halting. This value is entered in s (seconds) between 0.1 and 10. This parameter is manipulated along with the motor speed, load and rectified AC line voltage to simulate DC bus overvoltage condition during motor stop. A smaller Decel Rate value brings the motor to halt faster and will cause a higher voltage overshoot. In the IRMD26310DJ default configuration, when DC bus voltage exceeds 386V, the zero-vector mode of IRS26310DJ is activated. NOTE: The zero-vector insertion based DC bus overvoltage protection feature is triggered exclusively by IRS26310DJ and not by the digital control IC or software GUI. Hence no specific fault flags are displayed by GUI. However, since DC bus voltage has to exceed 360V before hitting the 386V limit when zero-vector insertion can occur, “DC bus Voltage Level Fault” message is displayed in GUI. www.irf.com © 2008 International Rectifier 20 t 1 CX1 0.1uF 250VAC 4 PTC/N5RL20 C34 VCC1 R17 2 2 DNI IRGIB10B60KD1 Q1 1 1 Q2 IRGIB10B60KD1 1 Q3 DNI DNI TP31 UG R61 UG 1 33 R99 3 3 3 TP39 +3.3V 3 R26 R27 R29 R30 R31 R32 4.7k 4.7k 4.7k 4.7k 4.7k 4.7k VS1 6 Hin1 Hin2 TP38 1 36 VB2 R63 D11 MBR0530T1 33 1 WG 33 R118 35 HO3 VB3 HO3 FLT/EN VS3 Itrip V 1 2 + - R122 DNI 2 U5 IRS2631 HO1 VB1 HO1 DCBSns HO2 VB2 MBR0530T1 33 HO2 VS2 C26 2.2uF, 25V 37 VB2 D10 R62 VG 33 R101 TP33 WG 1 1 41 42 MBR0530T1 33 TP32 VG C25 VB1 2.2uF, 25V 43 1 VB1 D9 DCB+ 4 3 1 1 1 1 www.irf.com 2 6 3 4 5 1 D POWER STAGE TP4 DCP DCP R35 1.00M + D6 D7 D8 470uF, 450V C36 2200pF R37 22.0K R123 0 DNI CAP1 VCC1 D CX2 0.1uF 250VAC 2 3 0.1uF,630V BR1 8GBU06 R36 1.00M DCBSns IRGIB10B60KD1 T1 LCL-UF1125 CY1 2.2nF C44 0.1uF TP14 GND R28 4.7k PWMVH PWMWH TP29 1 V PWMWL 30 29 GATEKILL R38 Itrip 13 23 LO1 22 LO2 21 LO3 20 R64 D12 33 R119 3 3 MBR0530T1 33 R65 33 D13 IFB TP24 COM 1 R60 GND 0.030, 3W R120 MBR0530T1 33 R66 33 D14 R121 MBR0530T1 33 /WG /VG 3 TP35 1 /VG TP36 1 /WG /UG 1 1 TP34 /UG 2 2 IRGIB10B60KD1 Q4 16 VSS COM 1 IRGIB10B60KD1 Q5 1 2 C37 100pF RCIN RCIN LO2 VCC1 C38 0.01uF 1M C24 10uF,25V C20 0.1uF C17 DNI 17 VCC LO3 R39 VCC1 VCC 14 LO1 20K 12 C27 2.2uF, 25V TP37 VB3 Lin3 TP28 1 U 11 31 VB3 TP22 GK PWMVL Lin2 10 PWMUL 9 Lin1 8 Hin3 7 TP15 GND PWMUH C45 10uF,10V 15 CY2 2.2nF C J1 C 1 2 3 4 5 6 7 8 EARTH LINE NEUTRAL GND DCP W V U JK55B-100-8 TP30 TP2 IFB IFB TP25 GND 1 1 1 TP26 GND TP27 GND 1 IRMD26310DJ – Circuit Schematics Figure 20: IRMD26310DJ power stage circuit schematic 21 Q8 VCC_short VCC R70 DNI R124 0 DNI R73 VCC_short 1 W W U IRGIB10B60KD1 Q6 B B Q9 DNI VCC1 C18 DNI R72 DNI VCC DNI R69 DNI 1 2 3 4 8 7 6 5 R71 DNI 1 2 3 4 DNI 8 R74 7 6 5 VCC1 A A IRMD26310DJ © 2008 International Rectifier 2 3 1 4 5 6 3 2 S1 CM309S4.000MABJTR C KT11P3JM Q7 MMBT3904LT1 B 1K +3.3V ISO4 1 2 3 4 VDD1 VOA VIB GND1 ADUM1201BR +3.3V CMEXT 28 CMEXT RESET TSTMOD R43 10K R88 4.7K C40 0.1uF 1 4 1 11 22 38 25 63 13 40 54 E C83 0.1uF 5V_I 5 R42 10K 4 nRST VDD2 VIA VOB GND2 8 7 6 5 C39 0.1uF DBRST VDD2 VDD2 VDD2 VDD1 PLLVDD + XTAL0 XTAL2 3 +3.3V 62 61 ISO3 R87 4.7K R89 4.7K RST TSTMOD C14 0.1uF 1 2 C5 10uF,10V U2-1 U2-2 Rd 10 U3 SN74LVC1G14DCK Rf 1M AVDD VDD1 VDD1 1 IFB TP23 IFBO GREEN 1 www.irf.com 2 6 3 4 5 C8 0.01uF 0.01uF 0.01uF C9 C10 1 1.8V C61 C62 C63 0.1uF 0.1uF 0.1uF TP12 RST CR1 1 2 C65 10uF, 10V +3.3V R25 4.7K D 5V_I R75 1K C69 0.1uF D R15 3 4 1.8V C96 C95 C3 C6 +3.3V CL2 CL1 15pF U2 2 C41 0.1uF 1.8V C84 10uF, 10V +3.3V J11 VCC GND GND 0.1uF 0.1uF 0.01uF 0.01uF 15pF DBRST_I R7 4.7K 5V_I R8 R10 R13 4.7K 4.7K 4.7K C42 0.1uF 6 2 10 4 8 5 9 1 3 7 DBRESET TMS TDI TCK TDO TRIG 3M 2510-6002UB R77 AREF C12 0.1uF R83 47pF, 50V C35 RED 11.8K + C31 10uF,10V TMS TDI TCK TDO AREF 29 GND R67 0 1.00K R81 5.11K TP42 AREF P5.1/TMS P5.3/TDI TCK P5.2/TDO 57 59 60 58 nRST_I TMS_I TDI_I TCK_I TDO_I C ADUM1401BRW C IFB+ IFBIFBO IFB+ IFBIFBO +3.3V R54 C33 100 pF 4 R6 0 R1 4.7K 0 2 LED1 1 R52 100 3 R53 100 LNJ115W8ARA +3.3V 5.11K R79 11.8K 31 30 32 From Shunt Resistor 16 15 14 13 12 11 10 9 VDD2 GND2 VOA VOB VOC VID VE2 GND2 VDD1 GND1 VIA VIB VIC VOD VE1 GND1 1 2 3 4 5 6 7 8 Current Shunt Feedback R80 1.00K R82 R55 R40 0 0 R68 0 RX1 TX1 J3 PRPN082PAEN From Shunt Resistor C4 33pF, 50V 1 1 1 1 1 1 C23 10nF ,50V J5 R3 DNI SCL/SDI-SDO SDA/CS0 R59 1.00K 1% TP10 VH TP6 UL TP11 UH 55 56 SCL SDA R11 1K R12 1K 1 21 1 2 3 4 5 6 VSS VSS VSS VSS PLLVSS AVSS PRPN061PAEN 470 12 23 39 53 64 26 470 470 470 470 470 R76 R84 R85 R86 R90 R91 AIN1 AIN2 AIN3 AIN4 AIN5 AIN6 AIN1 AIN2 AIN3 AIN4 AIN5 AIN6 27 33 34 35 36 37 R16 0 +3.3V C32 0.1uF IRMCF341 +3.3V C46 0.1uF C22 10uF,10V 8 7 6 5 C21 10uF,10V 8 7 6 5 U17 VCC WP SCL SDA A0 A1 NC GND AT24C512BN U20 VCC WP SCL SDA A0 A1 NC GND AT24C02BN 1 2 3 4 1 2 3 4 R14 0 R58 10K 21 Figure 21: IRMD26310DJ Digital Control & Communications Circuit Schematic 22 R20 AIN0 24 AIN0 R21 4.87K C43 2200pF TP8 WL TP9 WH TP7 VL P2.0/NMI P2.1 P2.2 P2.3 P2.4 P2.5 P2.6/AOPWM0 P2.7/AOPWM1 14 15 16 17 18 19 20 21 P2.0 P2.1 P2.2 VCC_short P2.4 P2.5 DAC0 DAC1 P1 +3.3V +3.3V 1.00M GATEKILL PWMWL PWMWH PWMVL PWMVH PWMUL PWMUH 41 42 43 44 45 46 47 GATEKILL PWMWL PWMWH PWMVL PWMVH PWMUL PWMUH P3.0/INT2/CS1 P3.1/AOPWM2 P3.2/NINT0 P3.3/NINT1 P3.5/T1 48 49 50 51 52 P3.0 DAC2 P3.2 P3.3 P3.5 +3.3V TP5 SCL ? R2 0 1 3 5 7 9 11 13 15 17 19 2 4 6 8 10 12 14 16 18 20 C97 0.01uF 0.01uF 0.01uF C98 C99 DC Bus Feedback DCP DCP R34 1.00M P1.0/T2 P1.1/RXD P1.2/TXD P1.3/SYNC/SCK P1.4/CAP P1.5 P1.6 P1.7 3 4 5 6 7 8 9 10 P1.0 RX1 TX1 P1.3 P1.4 P1.5 P1.6 P1.7 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 B B 1.8V GATEKILL PWMWL PWMWH PWMVL PWMVH PWMUL PWMUH R33 2.00K 1% 1 2 3 4 5 VCC_short DAC0 DAC1 +3.3V DAC2 R57 0 +3.3V JP1 R22 0 +3.3V JP2 J7 PRPN051PAEN R24 10K +3.3V R18 0 R19 0 A A C66 C67 C68 0.1uF 0.1uF 0.1uF IRMD26310DJ © 2008 International Rectifier 2 1 3 4 5 6 TP1 1 VSS 7 VC1+ EN FORCEON FORCEOFF 5V_I 6 ISO5 11 9 RX_I TX_I C29 0.1uF C50 0.33uF U4 3 V+ GND 2 4 5 +3.3V C54 0.33uF C30 0.1uF 1 www.irf.com 1 2 3 4 D TP16 5V_I RS-232 DRIVERS / RECEIVERS D 5V_I VCC 14 C52 0.1uF 15 MH1 J6 C51 0.33uF 1 5V_I 12 R44 16 R56 10 R78 C213 DOUT RIN MAX3221CDBR ROUT DIN 8 VDD1 VOA VIB GND1 DNI INVALID 0 C2+ 0 C1R41 0 C53 0.047uF C 1 2 3 4 5 6 7 8 9 C MH2 DB9RF 1 2 3 4 VDD2 VIA VOB GND2 8 7 6 5 TX1 RX1 ADUM1201BR 1 1 1 Figure 22: IRMD26310DJ RS-232 Drivers & Receivers Circuit Schematic 23 D/A FILTER R46 DAC0 TP18 DA0 R48 C92 1K 0.01uF 0.01uF 1K DAC0 B C89 B TP19 DA1 R47 DAC1 R49 C93 DAC1 1K 0.01uF FID1 1 FID3 1 FID5 1 C90 1K 0.01uF TP20 DA2 R50 DAC2 FID2 1 R51 C94 1K 0.01uF 0.01uF 1K DAC2 FID4 1 FID6 1 C91 A A IRMD26310DJ © 2008 International Rectifier 1 2 3 4 1 D4 6TQ045 9 L100 10uH, 3A 3 1 1 U103 R109 OUT IRFBG30 3 100 C108 R106 R111 8 GND C107 100pF 1K C111 470pF,50V R110 22K R112 1.0,1W 2 1 10nF,50V 10nF,50V C1 68uF,16V 5 6 U1 VIN FLAG GND GND IRU1208CS R108 47 D2 10MQ100N 100mA 7 2 VCC 1 UC3842D8 COMP VREF RT/CT 5 IS 3 8 C 1 1 www.irf.com 2 3 4 5 6 1 D FLYBACK POWER SUPPLY TP106 DCP DCP 1 R4 75K,1W 200K,1W 200K,1W D3 US1JDICT 2 LED2 LTL-16KE 47uF,35V C112 Q100 1 1000uF,16V 6 C113 470uF,16V C114 470uF,16V R113 1k TP17 GND TP101 GND C16 10uF,10V 0.1uF,50V C115 C117 C19 330pF,50V 330 R5 75K,1W C116 0.1uF,630V R114 R115 C118 270pF,1KV R9 10 R116 75K,1W R117 75K,1W T100 EE16 D DCP TP107 3.3V +3.3V 2 VFB 330pF,50V 1 68K R107 2.00K C R104 1.6K R105 5.1K C109 C110 4 TP3 1.8V 1.8V VOUT ADJ GND GND 3 4 7 8 R23 243 1.24 x ( 1 + 110/243) = 1.8 R45 110 1APea k 20 0mA ave C2 68uF,16V 1 B C100 NJM78M15FA 2 220uF,35V 100uF,25V C101 7 GND 10MQ100N C104 330uF, 25V 1 4 TP100 GND R100 FID101 1 1 C102 330pF,50V 5 FID103 330 VSS P la ce a p lat ed t hro ugh ho l e 2 GND 1 E100 f or f lyi ng l ead con nec tion FID100 1 1 FID102 R102 1M 6 A 1 Figure 23: IRMD26310DJ DC-DC Converter Low Voltage Power Supply Circuit Schematic 24 3 TP103 VCC VCC 3 OUT IN D1 1 D5 10MQ100N R103 10 U100 1 2 3 4 U31 Vin LM340T-5 Vout 3 5V_I B C105 TP13 330uF, 25V VSS A IRMD26310DJ © 2008 International Rectifier 1 5 6 IRMD26310DJ IRMD26310DJ – Bill of Materials 1 2 3 4 5 6 PCB CAP THR, 0.1uF 300VAC 20% X1 CAP SMT, 0.1uF 0805 CER 50V 10% X7R CAP THR, 0.1uF CER,630V CAP SMT, 0.01uF 0603 CER 50V 10% NPO/COG CAP SMT, 0.1uF 0603 CER 50V 10% X7R Panasonic ECQ-E6104KF Digikey EF6104-ND PCB, IRMD2631-R1.3 Panasonic ECQ-U3A104MG DIGIKEY P11116-ND 1 2 1 2 14 20 CX1,CX2 C117 C34,C116 C8-C10,C89-C99 C3,C6,C12,C14,C29,C30,C32,C3 9-C42,C44,C46,C61-C63,C66C69 C20,C52,C83 C38 C50,C51,C54 C53 CY1,CY2 C25-C27 C109,C110,C23 C5,C16,C21,C22,C31,C45,C65,C 84 C24 CL1,CL2 C4 C35 C115 C1,C2 C33 C37,C107 C100 C118 C101 C19,C102,C108 C104,C105 C111 C113,C114 C112 C36,C43 P1 @P1 CAP1 R2,R6,R14,R16,R18,R19,R22,R4 0,R41,R44,R54,R55,R56,R57,R6 7,R68,R123,R124 R60 R112 R59,R80,R83,R11,R12,R15,R46R51,R75,R111,R113 R20,R34,R39,Rf R35,R36,R102 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 CAP SMT, 0.1uF 0805 CER 50V 10% X7R CAP SMT, 10000pF 0805 CER 50V 10% X7R CAP SMT, 0.33uF 0805 CER 50V 10% X7R CAP SMT, 47nF 0805 CER 50V 10% X7R CAP THR, 2200PF 250VAC 20% Y2/X1 CAP SMT, 2.2uF 0805 CER 25V 10% X7R CAP SMT, 10000pF 0805 CER 50V 10% X7R CAP SMT, 10uF 3216 (A) TANT 16V 10% CAP SMT, 10uF 6032 TANT 25V 10% CAP SMT, 15pF 0603 CER 50V 5% NPO/COG CAP SMT, 33pF 0603 CER 50V 5% NPO/COG CAP SMT, 47pF 0603 CER 50V 5% NPO/COG CAP THR, 47uF, AL ELEC, 35V 2mmLS CAP SMT, 68uF 7343 TANT 16V 20% CAP SMT, 100pF 0603 CER 50V 5% NPO/COG CAP SMT, 100pF 0805 CER 50V 5% NPO/COG CAP THR, 100uF, AL ELEC, 25V 2mmLS CAP THR, CAP 270PF 1KV CERAMIC DISC GP 10% CAP THR, 220uF AL ELEC, 35V POL, (0.140"ls/3.5mm) CAP SMT, 330pF 0805 CER 50V 10% X7R CAP THA, 330uF, AL ELEC 25V CAP SMT, 470pF 0805 CER 50V 10% X7R CAP THR, 470uF, AL ELEC 16V 20% CAP THR, 1000uF, AL ELEC 16V 20% CAP SMT, 2200pF 0805 CER 50V 10% X7R CONN, HDR, 2x10 PIN 0.025" SQ POST GOLD (0.100"/0.230") CONN, SHUNT, 2-PIN SHORTING SHUNT CAP THR, 470uF,ELEC 450V 20% RES SMT, 0-OHM 1/8W 5% 0805 Panasonic EET-UQ2W471DA DIGIKEY P11951-ND SAMTEC TSW-110-07-S-D PANASONIC EEU-FC1V221L DIGI-KEY P10296-ND DIGIKEY P5164 KEMET T491A106K016AT T491A106K016AG Panasonic ECK-NVS222ME DIGIKEY P11420CT-ND 3 1 3 1 2 3 3 8 1 2 1 1 1 2 1 2 1 1 1 3 2 1 2 1 2 1 10 1 18 36 37 38 39 40 RES SMT, 0.03-OHM 3W 1% 1225 RES SMT, 1-OHM 1W 5% 2512 RES SMT, 1.0K-OHM 1/8W 1% 0805 RES SMT, 1.0M-OHM 1/8W 1% 0805 RES SMT, 1M-OHM 1/4W 1% 1206 1 1 15 4 3 www.irf.com © 2008 International Rectifier 25 ROTANGISED YTQ MANUFACTURER & PART# NOITPIRCSED TNENOPMOC # IRMD26310DJ ROTANGISED ROTANGISED ROTANGISED ROTANGISED R104 R33,R107 R1,R7,R8,R10,R13,R25-R32,R87R89 R21 R105 R81,R82 Rd R103 R24,R42,R43,R58 R77,R79 R38 R37,R110 R61-R66,R99,R101,R118-R121 R108 R106 R4,R5,R116,R117 R52,R53,R109 R23 R45 R114,R1115 R9,R100 R76,R84,R85,R86,R90,R91 D1,D2,D5 ISO4,ISO5 ISO3 U20 U17 Q1-Q6 U2 U5 U1 U4 D9-D14 Q7 Q100 U100 U103 D3 JP1,JP2 J11 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 RES SMT, 1.6K-OHM 1/8W1% 0805 RES SMT, 2.0K-OHM 1/8W 1% 0805 RES SMT, 4.7K-OHM 1/8W 1% 0805 RES SMT, 4.87K-OHM 1/8W 1% 0805 RES SMT, 5.1K-OHM 1/8W 1% 0805 RES SMT, 5.11K-OHM 1/8W 1% 0805 RES SMT, 10-OHM 1/8W 1% 0805 RES SMT, 10-OHM 1/4W 5% 1210 RES SMT, 10K-OHM 1/8W 1% 0805 RES SMT, 11.8K-OHM 1/8W 1% 0805 RES SMT, 20K-OHM 1/8W 1% 0805 RES SMT, 22K-OHM 1/8W 1% 0805 RES SMT, 33-OHM 1/8W 1% 0805 RES SMT, 47-OHM 1/8W 5% 0805 RES SMT, 68K-OHM 1/8W 1% 0805 RES SMT, 75K-OHM 1W 5% 2512 RES SMT, 100-OHM 1/8W 1% 0805 RES SMT, 243-OHM 1/8W 1% 0805 RES SMT, 110-OHM 1/8W 1% 0805 RES SMT, 200K-OHM 1W 5% 2512 RES SMT, 330-OHM 1/4W 5% 1206 RES SMT, 470-OHM 1/16W 5% 0603 DIODE SCHOTTKY 100V 1.5A D-64 IC DIGITAL ISOLATOR 4CH 16-SOIC IC DIGITAL ISOLATOR 4CH 16-SOIC IC SEEPROM 2K 2.7V SO-8 IC SEEPROM 512K 2.7V 8SOIC IGBT W/DIODE 600V 16A TO220FP DIGITAL CONTROL IC SOCKET SMT, 44L PLCC TIN SMD LDO REGULATOR IC IC SMT, MAX3221 RS-232 TRANSCEIVER 16L SSOP DIODE SMT, SCHOTTKY 30V 0.5A SOD-123 TRANS SMT, NPN 40V 200mA SOT-23 IC, MOSFET N-CH 1KV 3.1A TO-220AB IC 15V POSITIVE REGULATOR TO220F IC SMT, CUR-MODE PWM CONT 8-SOIC DIODE ULTRA FAST SW 600V 1A SMA CONN, HDR, 1x2 BREAKAWAY, 0.025 SQ GD (0.100"/0.230") CONN, HDR,2x5 3M .100" x .100" 4-Wall Header,Standard,Straight Through-Hole,10 Contacts,25106002UB IR 10MQ100N ANALOG DEVICE ADUM1201BR ANALOG DEVICE IC SMT, ATMEL AT24C02BN-SH IC SMT, ATMEL AT24C512BN-SH IR IRGIB10B60KD1 IR IRMCF341 TYCO/AMP 3-822516-1 DIGIKEY A97624CT-ND IR IRU1208CS MAXIM MAX3221CAE ON SEMI MBR0530T1G ON MMBT3904LT1G DIODES MMBT3904-7-F IR IRFBG30 NJR NJM78M15FA DIGIKEY NJM78M15FA-ND TI UC3842D8 DIGIKEY 296-11281-5-ND DIODES INC US1J-13-F SAMTEC TSW-102-07-S-S TSW-102-07-G-S 3M 2510-6002UB 1 2 16 1 1 2 1 1 4 2 1 2 12 1 2 4 3 1 1 2 2 6 3 2 1 1 1 6 1 NA 1 1 6 1 1 1 1 1 2 1 www.irf.com 26 YTQ YTQ YTQ YTQ MANUFACTURER & PART# NOITPIRCSED TNENOPMOC NOITPIRCSED TNENOPMOC NOITPIRCSED TNENOPMOC NOITPIRCSED TNENOPMOC # # # # © 2008 International Rectifier IRMD26310DJ ROTANGISED J7 J5 J3 U3 J1 S1 T1 U31 LED1 LED2 D4 BR1 L100 CR1 J6 T100 RT1 C17,C18,R3,R17,R69R74,R78,R122,D6-D8,Q8,Q9 U5 @Q1-Q6 @Q1-Q6 81 82 83 84 85 86 87 88 CONN, HDR,1x5 CONN, HDR,2x3 CONN, HDR,2x8 SINGLE SCHMITT-TRIGGER INVERTER CONN, 8P 10mm SWITCH SMT, SWITCH SPST MOM KEY J-LEAD SMD INDUCTOR MILLER_8103 1mH, 4.8A IC, REG, +5V, 1.0A, TO-220 SULLINS PRPN051PAEN SULLINS PRPN032PAEN SULLINS PRPN082PAEN TI SN74LVC1G14DCK ITT KT11P3JMDdigikey CKN9003CT-ND (BURNON LCL-UF1125) 1 1 1 1 1 1 1 NATIONAL SEMI LM340T-5.0 NOPB 1 ST Microelectroni L7805CV Digi-Key 497-1443-5-ND DIGIKEY P11142CT-ND 1 1 44 1 1 1 1 1 1 1 17 IR IRS26310DJPBF 1 ZHENJIANG HAOYANG HEAT SINK 1 COMPANY DS-480 6 ALLTHREAD 1929--3-A-01AAA 6 3 1 ALLTHREAD 1940--3--8-2A21A-0.5 PITCH 11 LITE-ON LTL-16KE DIGIKEY 160-1078-ND KEYSTONE 5002 DIGIKEY 5002K-ND IR 6TQ045 DIODE GBU806 JW MILLER 6000-100K-RC digikey M8616-ND Citizen CM309S4.000MABJTR digikey 300-8042-1-ND KYCON K22-E9S-NJ DIGI-KEY A23304-ND Precision 019-3214-03 GE sensing CL-60 Digikey KC006L-ND 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 LED SMT, 1.6x1.25mm BI-COLOR GREEN/ORANGE LED, T1 RED DIFF MISC, TEST POINT MULIT PURPOSE MINI WHT DIODE SCHOTTKY 45V 6A D2PAK RECT BRIDGE GPP 600V 8A GBU INDUCTOR HI CURRENT RADIAL 10UH OSC SMT, 4.0MHZ CRYSTAL 18PF CM309S CONN, D-SUB, 9P RECPT RT ANGLE W/ JACK SCREWS SMPS TRANSFORMER CURRENT LIMITER INRUSH COMPONENTS NOT POPULATED HIGH VOLTAGE GATE DRIVER IC HEATSINK insulating films for TO-220 heat sink HW, WASHER, M3, STEEL, SPLIT LOCK---LM7805 M3 * 8-3 M single screw, single-ended 3 M nuts, nylon, 6column-shaped isolation M3 * 8-3 M single screw, single-ended 3 M nuts, copper / stainless steel, six-column-shaped isolation HW, SCREW, #4-40 x 5/16" MACHINE PAN HEAD PHIL ZINC PLATED www.irf.com 27 YTQ MANUFACTURER & PART# NOITPIRCSED TNENOPMOC # © 2008 International Rectifier IRMD26310DJ IRMD26310DJ Specifications TC = 25°C unless specified Parameters Input Power Voltage Frequency Input current Input line impedance Output Power W atts Values 115V-230Vrms, -20%, +10% 50/60 Hz 4A rms @nominal output 4%∼8% recommended 400W continuous power Conditions TA =40°C, RthSA=1.9 °C/W Vin=230V AC, fPWM=10kHz, fO=60Hz, TA=40°C, RthSA=1.0 °C/W, Vertically mounted to help air flow RthSA limits ∆TC to 10°C during overload Current Host interface (RS232C) TXD, RXD DC bus voltage Maximum DC bus voltage Minimum DC bus voltage Current feedback Current sensing device Resolution Latency Protection DC Bus Overvoltage Protection by IRS26310DJ Output current trip level Short circuit delay time Critical over voltage trip Over voltage trip Under voltage trip Power Devices IRGB10K60D1 x 6 System environment Ambient temperature 3 Arms nominal, 9 Arms Overload 10V Typical 57.6 Kbps, single ended 400V 120V Should not exceed 400V more than 30 sec 33 mΩ dc link shunt 12-bit 1 pwm cycle Single shunt reconstruction PCB design may reduce the resolution 386V 14 A peak, typical Maximum 7 µsec 420 V 360 V 120 V o Zero vector insertion by IRS26310DJ Detection from shunt on negative DC bus line-to-line short, line-to-DC bus (-) short Zero vector insertion by digital controller Rated for 10A @100 C case with 10µs short circuit withstand capability Integrated over-current protection 0 to 40°C 95% RH max. (Non-condensing) Table 4: IRMD26310DJ Electrical Specification The information provided in this document is believed to be accurate and reliable. However, International Rectifier assumes no responsibility for the consequences of the use of this information. International Rectifier assumes no responsibility for any infringement of patents or of other rights of third parties which may result from the use of this information. No license is granted by implication or otherwise under any patent or patent rights of International Rectifier. The specifications mentioned in this document are subject to change without notice. This document supersedes and replaces all information previously supplied. For technical support, please contact IR’s Technical Assistance Center http://www.irf.com/technical-info/ WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245 Tel: (310) 252-7105 www.irf.com © 2008 International Rectifier 28