Eas y Aut omot ive Mo dules Applic atio n N ote Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) AN 201 2 -1 0 Revision 1.
Edition Revision 1.1 Published by Infineon Technologies AG 81726 Munich, Germany © 2013 Infineon Technologies AG All Rights Reserved. LEGAL DISCLAIMER THE INFORMATION GIVEN IN THIS DOCUMENT IS GIVEN AS A HINT FOR THE IMPLEMENTATION OF THE INFINEON TECHNOLOGIES COMPONENT ONLY AND SHALL NOT BE REGARDED AS ANY DESCRIPTION OR WARRANTY OF A CERTAIN FUNCTIONALITY, CONDITION OR QUALITY OF THE INFINEON TECHNOLOGIES COMPONENT.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Document Change History Date Version 09-2012 1.0 04-2013 1.1 Author T. Reiter T. Hoffmann T. Reiter T. Hoffmann Change Description Initial Version Added picture for CAN control more jumper position.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Table of Contents Page 1 1.1 1.2 Introduction ................................................................................................................................... 6 Safety Warning for Evaluation KIT .................................................................................................. 6 How to Order the Evaluation Kit .....................................................................................
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Table of Contents Page 9 CAN Messages ............................................................................................................................59 10 References ...................................................................................................................................
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Introduction 1 Introduction The Evaluation Kit “EASYKIT AUX DRIVES” was developed to support customers during their first steps in designing applications with the Easy 1B Automotive B6-Bridge power module. These modules are targeted for high voltage pumps and compressor applications within hybrid- and electric vehicles. The application note explains how to start with the Evaluation Kit and explains the design.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Quick Start Guide 2 Quick Start Guide Before operating this Evaluation Kit two steps are necessary: 1. Mount system on a cooling plate 2. Connect aux supply, HV supply and a 3phase AC motor (or alternative load) 3. Motor starts running automatically per default (see chapter 4 for CAN control modes) Please read the entire application note carefully in order to prevent accidents and damage on the Evaluation Kit. 2.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Quick Start Guide Figure 3 EASY AUX DRIVES Evaluation Kit mounted on a sample forced air cooler from Assmann WSW. Figure 4 Drawing of a sample forced air cooler (Assmann WSW: ASS_1060_HSrev01).
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Quick Start Guide 2.2 Connect Supplies and Load The Evaluation KIT has to be connected to a 8..18V auxiliary supply, which can deliver at least 2A. On the HV power connectors a supply <450V and a 3ph induction machine (or equivalent load) has to be applied. The connections are illustrated in Figure 5. Please take note that only the aux supply is reverse polarity protected up to -20V.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Quick Start Guide 2.3 Operation of Power Board only Some investigations, like typical double pulse switching tests, are easier to perform without a control board and software. The pulse patterns are generated here from a function generator. For such an operation, the power board needs some minor modifications. Three zero ohm bridges has to be placed. The location for these bridges are illustrated in Figure 6.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Quick Start Guide 2.3.1 Power Board Connector Description For Pin1 location please see Figure 6. No.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Quick Start Guide 2.4 Recommended Test Setup and Equipment Minimum to operate the Evaluation Kit: 8-18V/2A DC source 450V 20A DC source Cooler plate and thermal grease (see section 2.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Feature Description 3 Feature Description 3.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Feature Description 3.2 Protection Features The protection features in this Evaluation KIT are limited. Please take note that testing beyond maximum rating may lead to device failures and damages. Infineon will not take any liability for failures on the Evaluation KIT as well as damage on lab equipments. The design is not protected against: X Overtemperature X DCL Overvoltage (>450V) X Reverse polarity.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status 4 Operating Modes and LED status 4.1 Mode 1 (Default): Self test, soft start, and motor rotation This mode is selected per default in the standard delivery condition. After the Evaluation Kit has an appropriated supply voltage, first a self test is performed and after PASS result the phase output is ramped in a soft start function to a fixed output frequency.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status - The nominal output frequency has to be applied with CAN Message: CAN-ID 11hex, Signal Name PFacNom, Data Type Unsigned, Bit Start 0, Bit Length 16, Unit Hz Q6 (64 ↔ 1 Hz) - The target output frequency has to be applied with the CAN Message: CAN-ID 10hex, Signal Name DFacSet, Data Type Signed (negative value for change of rotation direction), Bit Start 16, Bit Length 16, Unit Hz Q6 (64 ↔ 1 Hz) -
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status LED1 LED2 Figure 9 Location of status leds. Led 1 is closer to the top edge of the control PCB. LED1 LED2 State Flashing quickly Flashing quickly Flashing quickly complementary to LED1 Off Off Flashing quickly On Off On Flashing slowly Self test, wait due to low DCL voltage. Increase >25V for continue operation.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status Figure 10 Control state machine of the Evaluation Kit. 4.5 Self Test Sequence A self test is implemented in the uC software, which is performed at each power up cycle of the control board. The Evaluation Kit will only start the normal operation, when the signals give reasonable values and the test sequence was performed successfully.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status Figure 11 Overview of self test sequence with the four major test procedures. The first part of the passive procedure checks the supply voltage of the uC and ADC. The ADC_1V95 signal is connected to the uC supply status led, which has a quite stable voltage drop of 1.95V over wide supply voltages. In case of drifts of the uC supply voltage, the ADC scaling of all sensors would not be correct.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status 25V Figure 12 Overview of the passive self test sequence. Part 1 to check ADC values on plausibility.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status The second part of the passive procedure checks the temperatures of the PCB and Module and cancels small current sensor offsets. The test procedure with the following switching test is only started if the Evaluation Kit is not in overvoltage lookout condition. Figure 13 Overview of the passive self test sequence. Part 2 to check ADC limit values.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status The passive tests are followed by switching tests of low side switches (see Figure 14) and high side switches (see Figure 15). Each switch is turned-on and Vce voltage, low side phase current, DCL voltage, and gate driver fault condition is checked for proper values. After this the switch is turned-off again.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status Figure 14 Overview of the active self test sequence. Part 1 to check the low-side switches.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status Figure 15 Overview of the active self test sequence. Part 2 to check the high-side switches.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Operating Modes and LED status 4.6 Motor Control (U/f) Concept The implemented simple U/f control concept is shown in Figure 16. The nominal frequency (FacNom) and voltage (VacNom) has to be adjusted to the specific motor. Higher output frequency than the nominal motor frequency enters the field weakening area. Figure 16 Motor control with U/f.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Evaluation Kit CAN Terminal 5 Evaluation Kit CAN Terminal 5.1 Introduction and Feature Description The Evaluation Kit has a CAN communication functionality, which can be used with all standard HighSpeed CAN toolsets (1MBit/s). This CAN communication is isolated from the high voltage potentials.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Evaluation Kit CAN Terminal 5.2 CAN Terminal Quick Start Guide The following steps are required to setup the CAN Terminal function: 1. Connect UConnect stick on your PC 2. Install SW on uConnect stick (see section 5.3) 3. Jumper CAN Control Mode on EASYKIT (see Figure 8) 4. Connect UConnect to EASYKIT CAN 5.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Evaluation Kit CAN Terminal 5.3 How to install SW on UConnect stick Before using the CAN Terminal via the Infineon UConnect stick a software has to be flashed into the UConnect microcontroller. The prepared SW is included in the shipped CD of the EASYKIT and can be found under “Software\Interface\uConnect” (see .hex file). The easiest way to flash the microcontroller is given with the Infineon MEMTOOL.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Evaluation Kit CAN Terminal nominal motor voltage phase to phase and type new voltage value – press enter to activate new value. The new value will be shown under the Feedback value column if value is accepted successfully from the EASYKIT. Other parameters, which are shown on the Terminal can be adjusted simply in the same way. If you want to perform single pulse tests you can switch to page 6 (see Figure 20).
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Evaluation Kit CAN Terminal Figure 20 CAN Terminal User Interface page 6 “Single Pulse Setup”.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 6 Experimental Results 6.1 Test sequence The test sequence concept was explained in Section 4.5. Figure 21 shows the measured waveforms from the mixed signal scope during the active switching part. The major events are numbered on the bottom of the screen shoot. Please take note that the phase voltages during switch turn-off phases can have different shapes depending on the connected load.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 6.2 Short Circuit Tests Short circuits can be considered as most critical events for an inverter. Two different types of short circuits were tested with the Evaluation KIT. Short circuit I is a short circuit close to the power module (e.g. on the power connectors) and thus has a low inductance. The short circuit II appears in the system if e.g. the motor windings generate a short.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results Tvj=25°C 30 500 25 400 20 300 15 200 10 100 5 0 0 -1 0 1 2 time [us] 3 4 Vge [V] Vce [V]; IL [A] 600 5 Figure 23 Measured waveforms of the DUT during the short circuit test. See Figure 22 for measurement points. 6.2.2 Short Circuit II (high inductance) An inductance between the power terminal of the phase output and the DCL+ terminal was inserted for the short circuit II tests.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results Figure 25 shows the measured waveforms of the IGBT (see Vce and Vge) and the short circuit current (IL). The IGBT turns-on at 0 us. Due to the short circuit inductance the current rises relatively low. After approx 16.5 us the current is high enough that the IGBT desatures (Vce voltage rises to high values despite the IGBT is still turned on).
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 6.3 IGBT Turn-off (300V, 25A, 150°C) The simplified circuit of the IGBT turn-off testbench is shown in Figure 26. Please note that the environmental conditions are different from a standard characterization testbench, where the maximum module performance is characterized. The gate driver has in this setup +15V/0V supply and Rg,off=2.2Ω. No booster stage is implemented.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 20 Vge [V] 15 10 5 0 50 500 40 400 30 300 20 200 10 100 0 Vce [V] IL [A]; Ic [A] -5 0 -10 -100 Eoff [uJ] 1500 1000 500 0 0 100 200 300 400 500 time [ns] 600 700 800 900 1000 Figure 27 IGBT turn-off at 300V, 25A and Tvj=150°C. Vge=+15V/0V with Rg,off=2.2Ω.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 6.3.1 IGBT Turn-on (300V, 25A, 150°C) The simplified circuit of the IGBT turn-on testbench is shown in Figure 28. Please note that the environmental conditions are different from a standard characterization testbench, where the maximum module performance is characterized. The gate driver has in this setup +15V/0V supply and Rg,on=2.2Ω. No booster stage is implemented. The gate driver achieves in this case ≈0.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 20 Vge [V] 15 10 5 0 -5 500 100 400 80 60 200 40 Vce [V] IL [A]; Ic [A] 300 100 20 0 0 -100 1000 Eon [uJ] 800 600 400 200 0 0 100 200 time [ns] 300 400 500 Figure 29 IGBT turn-on at 300V, 25A and Tvj=150°C. Vge=+15V/0V with Rg,on=2.2Ω.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 6.3.2 Diode Turn-off (300V, 25A, 150°C) The simplified circuit of the Diode turn-off testbench is shown in Figure 30. Please note that the environmental conditions are different from a standard characterization testbench, where the maximum module performance is characterized. The gate driver has in this setup +15V/0V supply and Rg,on=2.2Ω. No booster stage is implemented.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 500 40 400 300 0 200 -Vf [V] IL [A]; If [A] 20 -20 100 -40 0 -60 500 Erec [uJ] 400 300 200 100 0 -100 0 100 200 300 time [ns] 400 500 600 700 Figure 31 Diode turn-off at 300V, 25A and Tvj=150°C. Vge=+15V/0V with Rg,on=2.2Ω. Table 3 Measurement results during Diode turn-off (300V, 25A, 150°C) Symbol Unit Value Description Irm Erec di/dt Qrr trr A mJ kA/us uC ns 35 0.38 1.49 2.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results 20 Vge [V] 15 10 5 0 120 600 100 500 80 400 60 300 40 200 20 100 0 Vce [V] IL [A]; Ic [A] -5 0 0 100 200 300 400 500 600 700 800 900 1000 time [ns] Figure 32 IGBT turn-off at 450V, 100A and Tvj=25°C. Vge=+15V/0V with Rg,off=2.2Ω. Vce clamping measures are not needed in this Evaluation Kit. 6.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Experimental Results Figure 33 Evaluation Kit in motor run mode at 200V DCL voltage and 100Hz output frequency. Ch1-3 phase voltage U,V,W. Ch4 current phase U. D0: PWM_UB; D1: PWM_UT; D2: PWM_VB; D3: PWM_VT; D4: PWM_WB; D5: PWM_WT.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7 Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Power Board 7.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8 Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) Schematics Control Board 8.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) CAN Messages 9 Direction CAN Messages Msg.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) CAN Messages Direction Msg.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) CAN Messages Direction FsEasyKit 2Can Msg.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) CAN Messages Direction Msg.name, ID, DLC Update cycle De-bug1, write 022h, cycle 0.
Easy Automotive Modules Evaluation Kit EASYKIT AUX DRIVES (FS50R07W1E3_B11A) References 10 References The referenced application notes can be found at http://www.infineon.com Direct link to the Easy Automotive site: http://www.infineon.com/autoeasy [1] Infineon Application Note AN2010-09, “Explanation of Technical Information”. [2] Infineon Application Note AN2009-01, “Easy PressFIT Assembly Instructions”.
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