BP7B-LB

Description: The BP7B is a complete isolated interface circuit for six and seven pack G1-Series IPMs. This circuit features the VLA606-01R opto-interface IC for isolation of control signals and isolated power supplies for the IPM’s built-in gate drive and protection circuits. The isolated interface helps to simplify prototype development and minimize design time by allowing direct connection of the IPM to logic level control circuits. Features:  Complete three-phase isolated interface circuit with brake control and fault feedback  2500VRMS isolation for control power and signals  Standard AMP MTA .100” Input Signal and Control Power Connectors  Operates from a single 24VDC supply  Compact Size 4.0” x 2.5” (63mm x 102mm) Applications: BP7B is designed for use with Mitsubishi Electric G1-Series six and seven pack IPMs: 50A-450A 650V and 25A-200A 1200V.  Use Powerex VLA106-24151 and VLA10624154 DC to DC converters for isolated control power. See Table 1 for requirements. Ordering Information: BP7B-LS is a kit containing a bare PCB with one VLA606-01R and four VLA106-24151 DC to DC converters (See Table 1 for Compatible IPMs) BP7B-LB is a kit containing a bare PCB with one VLA606-01R opto-interface IC, three VLA106-24151 DC to DC converters and one VLA106-24154 DC to DC converter (See Table 1 for Compatible IPMs)) BP7B is a bare PCB only. Note: User must supply Optocouplers and passive components to fully populate the BP7B (See Table 2) 1 Publication Date: 6/12/17 Rev. 2 Application Notes BP7B – G1 Series Intelligent Power Module (IPM) Interface Circuit Reference Design Overview: A significant advantage provided by the G1-Series IPM’s built-in gate drive and protection circuits is that the entire family outlined in Table 1 requires only one interface circuit design. The interface circuit consists of opto-couplers to transfer control signals and isolated power supplies to power the IPM’s internal circuits. The devices have a common control ground for all three low side IGBTs. This permits use of a single low side supply so that only four isolated supplies are required. The Powerex BP7B reference design is an example of this circuit. Isolated DC to DC Converters: In order to simplify the design and layout of the required control power supplies Powerex has introduced the VLA106-24151, VLA106-24154 isolated DC to DC converters shown in Figure 2. Both DC to DC converters are designed to operate from a 24V DC supply and produce an isolated 15V DC output. The VLA106-24151 provides up to 100mA and the VLA106-24154 provides up to 300mA for control power. Both DC to DC converters use transformers to provide 2500VRMS isolation between the primary and secondary side. VLA106-24154 The BP7B board uses three VLA106-24151 DC to DC converters to provide high side control power for the G1 Series IPMs. The low side control power can be supplied by either a VLA106-24151 or VLA106-24154. The higher current VLA106-24154 is only needed when the current draw of the three low side gate drive circuits exceeds 100mA. Table 1 shows the recommended DC to DC converters for each G1 Series IPM. VLA106-24151 Figure 2: Isolated DC to DC Converters for IPM Control Power 2 Publication Date: 6/12/17 Rev. 2 Application Notes Table 1 - G1 Series IPM Line-Up and DC-DC Converter Selection Part Number Voltage Current Package Recommended DC(V) (A) DC Converters PM50[#]G1A(P)065 50 PM75[#]G1A(P)065 75 A PM100CG1A(P)065 100 VLA106-24151 x 4pc. (Order BP7B-LS) PM50[#]G1B065 50 PM75[#]G1B065 75 650 PM100[#]G1B065 100 B PM150[#]G1B065 150 PM200[#]G1B065 200 VLA106-24151 x 3pc. PM200[#]G1C065 200 VLA106-24154 x 1pc. (Order BP7B-LB) PM300[#]G1C065 300 C PM450[#]G1C065 450 PM25[#]G1A(P)120 25 A PM50CG1A(P)120 50 VLA106-24151 x 4pc. PM25[#]G1B120 25 (Order BP7B-LS) PM50[#]G1B120 50 B PM75[#]G1B120 1200 75 PM100[#]G1B120 100 VLA106-24151 x 3pc. PM100[#]G1120 100 VLA106-24154 x 1pc. PM150[#]G1C120 150 C (Order BP7B-LB) Figure 1 - G1 Series IPMs PM200[#]G1C120 200 [#] Circuit: C=Six pack, R=Six pack + Brake [P] Package Option: Empty = Screw Type, P = Solder Pin Type Example: PM75RG1AP065 is a 75A, 650V six pack with a brake in a solder pin type A package Figure 3 – BP7B Schematic J2 1 10 IC6 VLA106-24154/VLA106-24151 1 2 3 R2 R3 IC12 LED4 3 2 1 J3 IC4 IC3 Application Notes 11 10 9 8 LED1 IC5 VLA106-24151 3 2 1 VUP1 UP + UFO C1 VUPC J1 VLA106-24151 LED2 11 10 9 8 VVP1 VP + VFO C2 VVPC 3 2 1 4 3 2 1 + VWP1 WP + WFO C3 VWPC 11 10 9 8 +V LED5 C4 LED3 R4 VLA106-24151 R1 IC2 +C5 FO WN VN UN BR VN1 VN 27 26 25 24 23 22 18 17 16 15 16 17 8 9 10 11 IC1 11 10 9 8 40 39 38 5 37 36 35 34 33 32 VLA606-01R A complete schematic of the BP7B interface circuit is shown in Figure 3 and the bill of materials is given in Table 2. This circuit uses the VLA606-01R to transfer logic level control signals between the system controller and the IPM. The internal optocouplers provide galvanic isolation to completely separate the controller from the high voltage in the power circuit. The BP7B also provides isolated control power supplies to power the IPMs built-in gate drive and protection circuits. The six main IGBT on/off control signals (UP, VP, W P, UN, VN, W N) are transferred from the system controller to the IPM using the VLA606-01R. The IPM’s active low control inputs are pulled high by the VLA606-01R. An on signal is generated by turning on the internal optocoupler to pull the IPM’s control input pin low. The brake IGBT control signal (BR) is transferred from the system controller to the IPM using a low speed opto-coupler (IC1). The active low brake input pin on the IPM is normally pulled high by R1. When the BR control line (Pin 6 of CN1) is pulled low, current flows in the LED of the brake isolation optocoupler turning on its output and pulling the IPM’s brake pin low to activate the brake IGBT. If the IPM being used does not have the brake option then IC1, R1, and R2 can be omitted. +VL +WN +VN +UN BR +WP +VP +UP FO GND BP7B Circuit Explanation: G1 Series IPM Connector Table 2: BP7B Reference Design Component Selection Designation R1 R2 R3 R4 C1, C2, C3 C4 C5 LED1 - LED4 LED5 IC1 J1 J2 J3 IC2 IC3, IC4, IC5 IC6 Characteristic 4.7K, 0.25W 180, 0.25W 4.7K, 0.25W 1.8K, 0.25W 39F, 35V, 105C, Low imp. 150F, 35V, 105C, Low imp. 560F, 50V, 105C, Low imp. Super bright red LED Super bright green LED Slow Opto coupler NEC PS2501 2 position 0.1” right angle single row header 10 position 0.1” right angle single row header 2mm single row bottom entry header receptacle Powerex VLA606-01R Powerex VLA106-24151 Powerex VLA106-24151 or VLA106-24154 Description Brake input pull-up Input current limiter (15mA@VL=5V) Fault signal pull-up Power Indicator Current limiter Control power decoupling capacitor Control power decoupling capacitor DC to DC input decoupling capacitor Fault indicator LED Control power LED Brake signal isolator 24VDC Control power connector Control signal connector IPM connector Hirose Control and Fault signal isolator High side isolated DC/DC converter Low side isolated DC/DC converter Example Part Number CF14JT4K70 CF14JT180R CF14JT4K70 CF14JT1K80 EEU-FC1V390 EEU-FM1V151 UHE1H561MHD6 SSL-LX3044LID SSL-LX3044LGD PS2501-1-L-A 22-05-3021 22-05-3101 DF10-31S-2DSA(62) VLA606-01R VLA106-24151 VLA106-24154 3 Publication Date: 6/12/17 Rev. 2 - + Controller Interface: J1 J2 GNDFOUP VP WP Br UNVN WN+VL FO WN VN UN BR VN1 VNC VWP1 WP WFO VWPC IPM A typical controller interface for the BP7B is shown in Figure 4. An on signal (IPM control input low) is generated by pulling the respective control input low (GND) using a CMOS buffer capable of sinking at least 16mA (74HC04 or similar). In the off state the buffer should actively pull the control input high to maintain good noise immunity. Open collector drive that allows the control input to float will degrade common mode noise immunity and is therefore not recommended. If the IPM’s built in protection is activated it will immediately shut down the gate drive to the affected IGBT and pull the associated FO pin low. This causes the VLA606-01R to pull the fault feedback signal (Pin 9 of J2) low. When a fault is detected by the IPM a fault signal with a minimum duration of 1ms is produced. Any signal on the fault line that is significantly shorter than 1ms cannot be a legitimate fault and should be ignored by the controller. Therefore, for a robust noise immune design, it is recommended that an RC filter with a time constant of approximately 10μs be added to the fault feedback as shown in figure 4. An active fault signal indicates that severe conditions have caused the IPM’s self-protection to operate. The fault feedback signal should be used by the system controller to stop the operation of the circuit until the cause of the fault is identified and corrected. Repetitive fault operations may result in damage to the IPM. VVP1 VP VFO VVPC VUP1 UP UFO VUPC Printed Circuit Layout: Figure 5 shows the printed circuit layout of the BP7B interface circuit. The compact 63mm x 102mm circuit board with only 23 components provides a complete isolated seven channel driving circuit with short circuit, over temperature and under voltage protection. This clearly demonstrates the advantage of using G1-Series J3 Figure 4: BP7B External Connections 4 Publication Date: 6/12/17 Rev. 2 Application Notes The IPM’s fault output signals are transferred back to the system controller using low speed optocoupled transistors internal to the VLA606-01R. During normal operation the fault feedback line (pin 9 of J2) is pulled high to the +VL supply by the 4.7K resistor R3. When a fault condition is detected by the IPM it will immediately turn off the involved IGBT and pull its fault output pin low. The IPM’s fault output has an open collector characteristic with an internal 1.5k ohm limiting resistor. Current flows from the +15V local isolated supply to the low speed optocoupler LED (inside the VLA606-01R) and then to the IPM’s fault pin. The optocoupler’s transistor turns on and its collector pulls the fault feedback line low to indicate a fault. If any of the IPM’s four fault output signals become active; pin 39 of the VLA606-01R will be pulled low. Slow optos are used because they offer the advantages of lower cost and higher current transfer ratios. High speed is not necessary because the IPM disables a faulted device and produces a fault signal for a minimum of 2ms. The BP7B also includes an LED in series with each fault output (LED1-LED4) to provide a quick visual indication when the IPM’s fault signal is active. This was included for trouble shooting purposes only so it can be replaced by a jumper without affecting the operation of the interface circuit. Isolated control power for the IPM is supplied by Powerex isolated DC to DC converters (IC3, IC4, IC5, IC6) as described above. Each power supply is decoupled at the IPM’s pins with a low impedance electrolytic capacitor (C1C4). These capacitors must be low impedance/high ripple current types because they are required to supply the high current gate drive pulses to the IPM’s internal gate driving circuits. The DC to DC converters are powered from a single 24VDC supply connected at J1. The 24VDC supply is decoupled by the electrolytic capacitor C5 to maintain a stable well filtered source for the DC to DC converters. The current draw on the 24V supply will range from about 75mA to 300mA depending on the module being driven and switching frequency. For a more accurate estimate it is necessary to use the IPM’s circuit current (ID) versus fC characteristic to obtain the current required by the IPM being used. The IPM current draw can then be adjusted using the DC to DC converter efficiency specification to arrive at the current draw on the 24V supply. Refer to the general IPM application notes for detailed information. A power indicator consisting of an LED (LED5) in series with current limiting resistor (R4) is provided to show that the 24VDC supply is present. Intelligent Power Modules. One important feature of this PCB is the use of separate shield plane islands for each of the isolated driving circuits, logic level interface, and control power supply. Four of the islands are tied to the common of the IPM’s isolated control power supplies (pins 1, 5, 9 and 13 of J3). The remaining two islands are connected at the logic ground (pin 10 of J2) and 24 VDC power supply ground (pin 2 of J1) respectively. This layout is designed to prevent undesirable coupling of noise between the control side and the floating gate drive channels. The BP7B PCB is designed to plug directly onto the control pins of the G1-Series IPM. This configuration helps to maintain good noise immunity by providing minimal interconnection distance. Figure 5: Interface Circuit PCB layout Application Notes Component Legend Component Side Top Side 5 Publication Date: 6/12/17 Rev. 2 More Information: For more information refer to the following documents available from the Powerex website: The BP7B Board was designed for the purpose of evaluating and verifying the G1 Series IPM performance; reliability of the board is not considered. General environment was assumed for parts section. Care should be taken when selecting parts for the specific application environment and conditions. Please take precaution to avoid electric shock. We assume no responsibility for damage occurring while using the BP7B board. 6 Publication Date: 6/12/17 Rev. 2 Application Notes (1) G1-Series IPM individual data sheets provide the detailed electrical characteristics of G1-Series IPMs (2) Application Note – “General Considerations: IGBT & IPM modules”, Provides detailed information on power circuit design including bus bars, snubber circuits, and loss calculations. This document also includes heatsink mechanical requirements and proper mounting procedures. - http://www.pwrx.com/pwrx/app/IGBT-Intelligent-PwrMods.pdf (3) Application Note – “Introduction to IPMs (Intelligent Power Modules)”, Provides detailed information regarding features, operational characteristics, and interface circuit requirements for Intelligent Power Modules. http://www.pwrx.com/pwrx/app/IntellimodIntellPwrMods.pdf (4) Application Note – “IPM L1/S1-series”, Provides detailed information regarding features, operational characteristics, and interface circuit requirements for the L1/S1 Series IPMs. http://www.mitsubishielectric.com/semiconductors/files/manuals/ipm_l1_s1_note_e.pdf (5) VLA106-24151 and VLA106-24154 individual data sheets provide detailed electrical characteristics for these DC to DC converters. (6) Melcosim loss simulation software - provides quick power loss estimation for G1-Series IPMs in three phase inverter applications. - http://www.pwrx.com/Login.aspx?arrival=LossSimulation Keep safety first in your circuit designs! Powerex puts the maximum effort into making semiconductor products better and more reliable, but there is always the possibility that trouble may occur. Trouble with semiconductors may lead to personal injury, fire or property damage. Remember to give due consideration to safety when making your circuit designs, with appropriate measures such as (1) placement of substitutive, auxiliary circuits, (2) use of non-flammable material or (3) prevention against any malfunction or mishap. Notice regarding these materials Application Notes These materials are intended as reference to assist our customers in the selection of the Mitsubishi semiconductor product best suited to the customer‘s application; they do not convey any license under any intellectual property rights, or any other rights, belonging to Powerex or any third party. Powerex assumes no responsibility for any damage, or infringement of any third-party‘s rights, originating in the use of any product data, diagrams, chart, programs, algorithms, or circuit application examples contained in these materials. All information contained in these materials, including product data, diagrams, charts, programs and algorithms represents information on products at the time of publication of these materials, and are subject to change by Powerex without notice due to product improvements or other reasons. It is therefore recommended that customers contact Powerex or another authorized Mitsubishi Semiconductor product distributor for the latest product information before purchasing a product listed herein. The information described here may contain inaccuracies or typographical errors. Powerex assumes no responsibility for any damage, liability, or other loss rising from these inaccuracies or errors. Please also pay attention to information published by Powerex by various means, including the Powerex home page (www.pwrx.com) When using any or all of the information contained in these materials, including product data, diagrams, charts, programs and algorithms, please be sure to evaluate all information as a total system before making a final decision on the applicability of the information and products. Powerex assumes no responsibility for any damage, liability or other loss resulting from the information contained herein. Mitsubishi Electric Corporation semiconductors are not designed or manufactured for use in a device or system that is used under circumstances in which human life is potentially at stake. Please contact Powerex or another authorized Mitsubishi Semiconductor product distributor when considering the use of a product contained herein for any specific purposes, such as apparatus or systems for transportation, vehicular, medical, aerospace, nuclear, or undersea repeater use. The prior written approval of Powerex is necessary to reprint or reproduce in whole or in part these materials. If these products or technologies are subject to the Japanese export control restrictions, they must be exported under a license from the Japanese government and cannot be imported into a country other than the approved destination. Any diversion or re-export contrary to the export control laws and regulations of Japan and/or the county of destination is prohibited. Please contact Powerex or another authorized Mitsubishi Semiconductor product distributor for further details on these materials or the products contained therein. 7 Publication Date: 6/12/17 Rev. 2