APPLICATION NOTE

POWER CARD FOR MOTOR DRIVE

Florian GRALHON GE3

Customers : RENESAS : Vincent MIGNARD, Tolentino MARTINS Industrial tutor : Jean-Yves RIGNAULT Technical tutors : Michel JAMES, Jean-Pierre PLUMEY

SUMMARY
1. 2. 3. a. b. c. 4. a. b. c. Introduction..................................................................................................................................... 3 General diagram .............................................................................................................................. 3 Rectifier board ................................................................................................................................. 4 Board plan ................................................................................................................................... 4 Components choices ................................................................................................................... 4 Test protocol ............................................................................................................................... 5 Inverter Board ................................................................................................................................. 6 Board plan ................................................................................................................................... 7 Components choices ................................................................................................................... 8 PCB design ................................................................................................................................. 13

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1. Introduction
The power card allows to supply an 1 kW engine (3 * 230 V) starting from the network standard single-phase current. It has to be compatible with all the techniques of vectorial ordering of polyphase motors. It has several sensors to measure the voltage, phase engine currents and the speed. The board has a lot of galvanic isolation to allow the protection of our equipment during the tests. However, this board will not have isolation for the final version because these components are very expensive and they are useless if the board functions. This board is divided in two boards. The first is called rectifier board. It allows to rectify the sector voltage and the other inverter board which allow to have a three phase voltage and to measure current, voltage and speed.

2. General diagram

Figure 1 : general diagram In first time, the mains voltage is rectified with a diode bridge and then smooth with capacitors (rectifier board). After this direct voltage is transformed in alternative three phase voltage to drive the engine (inverter board). The main component which allow to rebuild this alternative voltage is a module for appliance motor drive IRAMS 10UP60A. It contains 6 IGBT, drivers and protection. The switching of IGBT is driven by the microcontroller board.

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3. Rectifier board
a. Board plan

Figure 2 : rectifier board

Like we have said previously, this board allows to have a direct voltage. It has a diode bridge and two capacitors to smooth voltage. There is also three protection components. A fuse which protect against over current. A thermistor NTC protect against strong current starting and a varistor against ever voltage.

b. Components choices
Diode bridge : The diode bridge is a GBPC2502 by the manufacturer International Rectifier. Its maximum output current is 20A under capacitive load. In our application, we evaluate a nominal current at 3A. However, it can increase a lot because of the torque of motor or the starting current. It is oversized on account of the strong peak current gives rise to the rectifier capacitors. Rectifier capacitors: Two capacitors in shunt connected are used. The manufacturer is Epcos and theirs values are 470F. This value has been calculated with the formula : 100 = 1mF with = 30V. The two capacitors in shunt connected allow having a value of 1mF. Varistor: The varistor is S20K275 of Epcos. It is in shunt connected with the protected circuit. At rest it has very high impedance and doesnt modify the circuit characteristics to protect. In the presence of electrical impulse, the varistor impedance decreases a lot and become a short circuit and so protects the circuit. The varistor chosen limits the voltage at 275V RMS. Thermistor NTC : 06/01/2008
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POWER CARD

The NTC are thermistors with a resistor which decrease uniformly with temperature. It allows protecting the board against current at the starting voltage. Put a thermistor in series with power supply will limit raises current created by inductive or capacitive load. The power losses of this component are 3W. It has been determined with the datasheet:

I: Thermistor current K, n: Thermistor coefficients (1.55, -1.37) Rntc: Thermistor rsistance P= R* I = 3W

c. Test protocol
Rectifier board simulation

A simulation with the software PSIM has been done to observe the current of the diode bridge in order to size it.

Figure 3: rectifier board simulation Current peaks can reach 38A. The voltage wave is 25V. POWER CARD 06/01/2008
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Discharged test

In first time, we test the board discharged. In theory, the output voltage waited was 230*sqrt(2)=325V. With a voltmeter we have noted 320V because the voltage isnt very direct but there is wave. Loading test

Because of the engine is a 3A motor, we have created a resistive load with resistor to have a 3A current. The component temperatures are 48C for the diode bridge and 52C for the thermistor. And so finally in checking on the datasheet we can validate the good working of the board. The power losses for the diode bridge are: P = U*I = 2 * 0.7 * 3 = 4.2 W. The coefficient 2 is the number of diode which conducts all the times. Output voltage signal and output current signal are visible on the figure 4. The output voltage is approximately 310V. We see the voltage isnt perfectly direct. There is a wave of 25V.

Figure 4 : Rectifier board signals

4. Inverter Board
Power supplies +15V and +5V are required to supply components.

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a. Board plan

Figure 5 : inverter board POWER CARD 06/01/2008

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b. Components choices
Integrated power module IRAM10UP60A

This integrated power module has 6 IGBT and it is optimized for electronic motor control in appliance applications such as washing machines. Plug N Drive technology offers an extremely compact, high performance AC motor-driver in a single isolated package for a very simple design. Its maximum PWM Carrier Frequency is 20KHz. Its maximum current is 10A ant its maximum positive bus input voltage is 450V. It owns its drivers and temperature protection. This component has been studied for a functioning of 3A, a bus voltage of 320V and a switching frequency of 20KHz.

A protection against module over temperature is present. A divider bridge voltage with a thermistor NTC allows switching off the circuit when the temperature is hot. The thermistance resistance becomes weak when temperature increases. So the protection voltage T/Itrip increases and when it exceed 3.3V the integrated power module switch off its functioning.

Figure 6: thermistor Built-in IRAMS10UP60A Bootstrap Capacitors are required to the high part module IGBT because they arent referenced to the ground but with regard to the variable phase voltage. Capacitors values are 2.2F in our application.

Figure 7: Recommended minimum Bootstrap Capacitor value Vs Switching Frequency

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The power losses estimated are: Switching losses:

Switching-on losses: W = (V_BUS*I*Ton)=0.5*320*3*100*10e-9=48J Pon = W*F= 0.96W

With W : energy switching losses V_BUS : bus voltage I : IGBT current Ton : switching-on time (datasheet = 100ns) F : switching frequency

Figure 8: IGBT Turn-on. Typical turn-on waveform current=5A , VBUS=400V

Switching-off losses : W = (V_BUS*I*Toff)=0.5*320*3*130*10e-9=62JJ Poff = W*F=1.248W With W : energy switching losses V_BUS : bus voltage I : IGBT current Toff : switching-off time (datasheet = 130ns) F : switching frequency

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Figure 9: IGBT Turn-off. Typical turn-off waveform current=5A , VBUS=400V So total switching losses are : Psw = Pon*6 + Poff*6 = 13.25W

Conduction losses are: Pcond = 2*Vce(sat)*I = 2*1.5*3 = 9W With Vce(sat) : IGBT conduction voltage I : IGBT current Total power losses estimated are 22.25W. A heat sink is placing vertically with regard to the PCB. The cooling fin is equally vertically to allow a natural convection (figure 10) and so we can avoid a cooling fan. The heat sink has a thermal resistance of 5.38C/W.

Figure 10 : module mounting method

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hall-effect current sensor

Hall-effect current sensors allow to have the phase motor current. The sensors used are LTS-6NP of manufacturer LEM. With the hall-effect technology, they insulate the power part and the order part with a very good accuracy of 0.2 % and a linearity error lower than 0.1 %. They can measure a rated current of 3A. Theirs power supplies are 5V like the input ADC. A RC filter with a cut frequency of 1.5 KHz allows to filter the switching noises.

Voltage sensor

A divider voltage bridge has to measure the bus voltage. It divides the voltage by 76, thus 380V equal 5V which is the ADC reference. A RC filter with a cut frequency of 1.5 KHz allows to filter the switching noises.

Shunt current detection

It allows to measure the current in bus supply. This measurement is used to the OSCD (One Shunt Current Detection) technology. The measured voltage is amplified with an amplifier from Analog Devices. A RC filter with a cut frequency of 1.5 KHz allows to filter the switching noises. The shunt value is 0.1 and the amplifier amplifies by 5. So the maximum 5V of ADC correspond to 10A. If the maximum current isnt enough high, we can decrease the amplifier gain with a potentiometer and so have a maximum current of 20A for example.

Protection against energy back

The protection IGBT used is STGF7NC60HD from ST. It has to be very fast to respect its function. A high speed comparator LM319 allow to compare the bus voltage with a reference. A driver allows the good switching. This protection activate itself when there is an energy back generated by the decreased speed and become upper than 380V. So the energy is transferred to a power resistance. This protection is in shunt connected with the rectifier capacitors which can have a maximum voltage of 400V.

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Figure 11 : diagram protection Speed measurement

A wiring done of a high speed comparator LM319 (response time: 80ns) supplied with 5V allows to have the motor speed. The motor dynamo does a 20V maximum sine curve. A divider bridge divide the voltage by 4 to get a 5V maximum voltage (the diagram described isnt the same than on the inverter diagram). With the LM319, we transform the sine curve on a square signal for use it with the microcontroller. A RC filter with a cut frequency of 1.5 KHz allows to filter the switching noises. Signals are visible on the figure 12.

Figure 12 : speed measurement signals

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c. PCB design
The Board PCB Design has to be done with carefully because EMC is very embarrassing to the good functioning. At first, the power and the order has to be well separated to avoid the pollution of measurements and digital signals. The wires length must be as short as possible and avoid to do loop. Circuit lines can become unintentional "antennas" for ambient signals and noise, especially if their length is close to the wavelength of a harmonic of the primary frequency. Capacitors of 100nF have to be placed next to supplies components. RC filters must be placed before all measurements and others signals if they are pollute.

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