Intelligent Power Module for Motor Control

Chapter 1 Introduction

1.1 Technical Specifications

1.2 Block Diagram

1.3 Detailed Features of Cards Involved

Chapter 2 Pictorial View

2.1 Connection Details

2.2 Part Number of Different Components Used

Chapter 1 Introduction

Intelligent Power Module for Motor Control is developed with protection and sensing circuit for different motor drives. It is intended to quickly implement a digitally controlled; six switch DC/AC inverter fed motor drives. The unit can also be utilized for solar and renewable energy types of applications as well as stands alone sine or space vector inverter designs. The unit can also be used for power quality improvement solution like reactive power compensations using different topologies.

1.1 Technical Specifications
Intelligent Power Module for Motor Control is provided with the following Specifications -

• Maximum Input Voltage: Three Phase 415 V, 50 Hz, 10 A

• DC Link Voltage: 600 V, 12 A

• Output: 400V/10 A

• 1200 V, 25 A diode bridge for AC-DC power conversion

• 02 numbers of 4700 MFD, 450V Electrolyte DC capacitor

• Three phase 1200 V, 30 A IGBT power module with appropriate heat sink and snubber.

• Highest switching frequency of the inverter 20 kHz

• Port for connecting 06 gate pulses to drive IGBTs of the inverter circuit

• IGBTs with desaturation protection against overload and short-circuit

• Indication of READY and FAULT with a provision to latch driver output and RESET button.

• Fault output for communicating FAULT status to the Microcontroller

• Sensor Circuit: Sensing circuit for Three AC output currents, One DC current and One DC voltage, 03 AC voltage sensors are provided separately for grid synchronized application.

• All cards are mounted in Transparent Acrylic box and power terminals, control terminals and sensor feedback are terminated on front panel.

1.2 Block Diagram
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1.3 Detailed Features of Cards Involved
The distinct features of Driver card and Sensor card are detailed below:

IGBT Driver Card:

• Suitable for 600V, 25 A IGBTs

• 2 A rail-to-rail output

• Individual six channel isolated IGBT driving

• Input pulses: CMOS 0-5 V or 0-3.3 V (Active high pulse)

• Output pulses: Isolated +16V/-8V

• Shoot through, Short circuit protection with DESAT-detection

• On board hardware dead time generator circuit (1 µSec)

• 06 SMPS for generating +16V/-8V isolated power supplies required for driver IC

• Inhibiting all gate pulses during any abnormality/hardware error/FAULT condition

• RESET to start gate pulses after clearing the FAULT. Driver can be RESET via on board switch or external reset pulse.

DC Voltage Current Sensor Card:

• One DC voltage measurement

• One DC current measurement

• Isolated measurement

• Output restricted to 0-3V below unipolar ADC reference

• Hall-current Sensor Specifications: Output voltage Vout 4V, Output Impedance <150 ohm,

Load Resistor >10Kohm, Vcc Supply Voltage: ±15V ±5%, Accuracy <1%, Linearity <1% and Frequency Bandwidth 50 kHz

• Hall-voltage Sensor Specifications: Primary Voltage Measuring Range 10 - 500 V, Primary nominal rms current 10 mA, Secondary nominal rms current 25 mA, Overall accuracy ±0.9 %, Linearity error <0.2 %

• DC Voltage Sensing: Input Voltage: 0-650 VDC, Conditioned output: 0-3 VDC

• DC Current Sensing: Input Voltage: 0-12 Amp, Conditioned output: 0-3 VDC

Three Phase AC Voltage and Current Sensor Card:
• Isolated measurement

• Output restricted to 0-3V (peak-peak)

• Unipolar output with DC offset

• Suitable for interfacing with unipolar ADC channel

• AC Current Sensing: Input: 0-10 Amp, Conditioned output: 0-3 VDC, Offset: 1.5 VDC

• AC Voltage Sensing: Input: 0-230 VPN, Conditioned output: 0-3 VDC, Offset: 1.5 VDC

The pictorial view and details of terminal are shown in next chapter.

Chapter 2 Pictorial View

The pictorial view and front panel sticker of the module are as shown in following figures:

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2.1 Connection Details
The different sections of the module are explained below:

i. Control Supply
Connect 230 V, 50 Hz single phase AC source to the kit by plugging power cord of the unit. This will provide control supply to the unit.

ii. Rectifier Input
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User can connect 415 V; 50 Hz three phase AC Supply at these terminals. It is recommended to connect it through variac in order to control DC link voltage.

iii. DC Short Links

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Short this DC links for connecting rectifier input to the inverter section.

For connecting external Low DC voltage, do not short this links and provide low DC supply externally may be 24 V DC SMPS connected to the inverter.

iv. Gate pulses
User should connect gate pulses of 5 V from any controller at this terminal.
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NOTE: On Fault, Remove Gate pulses first then press RESET.

v. AC Voltage Sensor Connection
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For the applications where grid synchronization is required, three AC voltage sensors with phase voltage 230 V is provided.

User can connect three phase voltages externally between these terminals.

vi. Sensor Outputs
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Sensor outputs are derived from following terminals.

  1. Three AC Inverter Output Currents;

  2. One DC link Current;

  3. One DC link Voltage; and

  4. Three AC voltages sensors connected for grid synchronization.

The output of these sensing circuits can be observed on oscilloscope at above terminals. The same can also be connected to ADC input of microcontroller for connecting theses feedbacks to the controller.

The output of different sensor and its calibrations are as listed below:

  1. DC Voltage: Input: 0-650 VDC, Conditioned output: 0-3 VDC;

  2. DC Current: Input: 0-12 Amp, Conditioned output: 0-3 VDC;

  3. AC Currents: Input: 0-10 Amp, Conditioned output: 0-3 VDC, Offset: 1.5 VDC; and

  4. AC Voltages: Input: 0-230 V PN, Conditioned output: 0-3 VDC, Offset: 1.5 VDC

vii. Driver Circuit Status
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Driver status indications for Fault and Ready signals are provided.

Feed power to power circuit only if driver status is healthy.

On fault with inverter, Fault LED becomes on and all gate pulses are blocked.

Use Reset switch for resetting driver card after clearing the fault.

If Fault occurred, then after solving Fault stop Gate pulses first and then press Reset.

NOTE: On Fault, Remove Gate pulses first then press RESET.

viii. Output Terminals
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It is three phase output of the inverter.

At these terminals user can connect Load and Observe Inverter Output on oscilloscope.

2.2 Part Number of Different Components Used

  1. Diode Bridge - B6U100A16

  2. IGBT Module - SKM75GB12T4

  3. IGBT Snubber Capacitor – 0.47 or 1MFD/1000V CTR

  4. Hall Voltage Sensor - VSLV025C, Hall Current Sensor 25A - TC 25A

  5. Infineon Driver IC 1ED020I12-F2