agileswitch gate drivers hpfm-hpm fiber series user manual

HPFM-HPMTM Fiber Series Manual

HPFM-HPM-Fiber Series Manual V03 PRELIMINARY of 20

AgileSwitch Gate Drivers HPFM-HPM Fiber Series

User Manual



Contents Abstract ................................................................................................................................................................... 3

Key Switch Driver Features ................................................................................................................................ 3

Applications ........................................................................................................................................................ 3

AgileSwitch Handling Instructions ......................................................................................................................... 3

ESD Protection .................................................................................................................................................... 3

Hot Swapping ...................................................................................................................................................... 3

Soldering and Mounting Instructions .................................................................................................................. 3

Recommended Start-Up Testing ............................................................................................................................. 4

Mechanical Dimensions .......................................................................................................................................... 5

System Overview .................................................................................................................................................... 6

Absolute Maximum Ratings ................................................................................................................................... 7

Electrical Characteristics ......................................................................................................................................... 7

Interconnects ........................................................................................................................................................... 8

Interconnects (Continued) ............................................................................................................................... 9

Timing Diagrams .................................................................................................................................................. 10

Timing Diagram Values ........................................................................................................................................ 11

Description of Features ......................................................................................................................................... 12

Two-Level Turn-Off (2LTO)/ Soft Shut Down (SSD) ..................................................................................... 12

Desaturation Detection (Short Circuit Protection) ............................................................................................ 14

Active Clamping ............................................................................................................................................... 16

Under Voltage Lockout (UVLO) ...................................................................................................................... 17

Input and Output pins of the HPFM Gate Driver Board ....................................................................................... 17

Generic Sample Factory Settings .......................................................................................................................... 17

Generic Sample Factory Settings – Fault and Monitoring Conditions ................................................................. 18

Fault/Status Reporting Information ....................................................................................................................... 18

Fiber Connectors-Logic .................................................................................................................................... 18

Legal Disclaimer ................................................................................................................................................... 20

Patent Notices........................................................................................................................................................ 20

Manufacturer ......................................................................................................................................................... 20



Abstract The AgileSwitch HPFM-HPM Fiber driver provides monitoring and fault reporting information to enable better

control and analysis of an IGBT-based power system. The HPFM provides up to 30 Amps of peak current at an

operating frequency up to 15 kHz. The driver includes an isolated DC/DC converter and provides a single fault

that is reported via the dual channel fiber I/O. All AgileSwitch drivers use automotive temperature grade

components and allow for modifying settings of gate resistors and active clamping.

Key Switch Driver Features

2-level turn-off time and voltage level

Soft Shut Down (SSD) time and voltage level

Desaturation time and voltage level

Master-Slave capability for parallel operation

Gate drive voltage +15V/-10V

Peak gate current +30A/-20A

Suitable for IGBTs up to 3300V

Power supply under-voltage lockout (UVLO)

1 X 7W output power

Applications

Solar/PV Inverters

Wind Turbines

UPS

HEV/EV

Motor Drives

High Speed Trains/Traction

Induction Welding, Cutting and Heating

Frequency Conversion

AgileSwitch Handling Instructions

Engineers and technicians handling AgileSwitch Gate Drivers are asked to read this document carefully to fully

understand the proper handling of AgileSwitch products. Failure to follow these guidelines may result in a dead

board or a system failure. Precautions outlined in this section include ESD Protection, Hot Swapping, Start-Up

Testing, and Mounting Instructions.

ESD Protection

All AgileSwitch Gate Drivers are Electrostatic Discharge (ESD) Sensitive. Each board is

packaged in an ESD bag with an ESD sticker on it.

1. Prior to removing the board from the bag, technicians should be grounded using a grounding

mat with an antistatic wrist strap.

2. AgileSwitch recommends using a steel work bench for optimal ESD protection.

Hot Swapping

The term hot swapping describes plugging or unplugging cables while power is applied to the system. This

action is not recommended on AgileSwitch products. The products enclosed in this package may be described as

cold-pluggable. This means that the system must be powered down in order to plug/ unplug a cable to/from an

AgileSwitch gate drive board. Failure to do so may result in a damaged gate drive board.

Soldering and Mounting Instructions

Please refer to the Application Manual from your respective IGBT manufacturer.



Recommended Start-Up Testing

Caution: Handling devices with high voltages involves risk to life. It is imperative to comply

with all respective precautions and safety regulations.

When installing the 4 pin power/controller to driver connector, please make sure that

power is turned off. Hot swapping is not recommended.

AgileSwitch assumes that the gate drive board has been mounted on the IGBT prior to start-up testing. It is

recommended that the user checks that the IGBT modules are operating inside the Specified Operating Area

(SOA) as specified by the IGBT manufacturer including short circuit testing under very low load conditions.

These tests should be performed before system installation:

1. Connect dual channel fiber I/O lines from your controller to the driver.

2. Connect the driver through the 4 pin power header unpowered to your drive electronics.

3. Supply the driver with +15V.

4. Initiate the drive signals.

5. Check the gate voltage:

a. For the off-state, the nominal gate voltage (Vge) should be -9V to -12V.

b. For the on state, Vge is +14V to +16V.

c. Check that the supply current of the driver is within spec with inactive trigger signals and then at the

desired switching frequency.

6. The system is now ready for application testing under load conditions.

7. Check the Thermal Conditions to verify that the system is operating within the specified temperature range.

Figure 1



Mechanical Dimensions

Download the full drawing and model for additional details. Not all components are shown.

HPFM Drawing

HPFM .STEP Model

Figure 2: Dimensions of the HPFM-HPM Fiber Series IGBT driver in millimeters (mm). (+/- 0.1mm)

https://dl.dropboxusercontent.com/u/18470390/HPFM%20Drawing.pdf

https://dl.dropboxusercontent.com/u/18470390/HPFM-HPM%20Fiber%20Master.STEP



System Overview

The basic topology of the driver is shown in Figure 3.

Figure 3: Basic schematic of the HPFM-HPM IGBT driver



Absolute Maximum Ratings Interaction of maximum ratings is dependent on operating conditions

Parameter Description Min Max Unit

Supply Voltage VCC to GND 0 18 V

Peak Gate Current Note 1 -20 +30 A

Output Power per Gate 7.0 W

Switching Frequency Note 2 0 15 kHz

Isolation Voltage Primary to Secondary VAC RMS 1 min 6000 V

Working Voltage Primary to Secondary, Secondary to Secondary 3800 V

Creepage Distance Primary to Secondary Side 25 mm

𝑑𝑉/𝑑𝑡 Rate of change input to output 50 kV/μs

Operating Temperature -40 +85 °C

Storage Temperature -40 +90 °C

Electrical Characteristics

Conditions: VSUP = +15.0 V

Power Supply Description Min Typ Max Unit

Supply Voltage VCC to GND 14.5 15 16 V

Supply Current Without Load – Note 3 90 110 mA

Average Supply Current Note 3 170 mA

UVLO Level Secondary Side low voltage detect fault level 12 12.8 13.5 V

UVLO Shut down Gate Drive Lock Out 8.8 9.0 9.3 V

Soft Shut Off Voltage(VSOFT) 8.2 8.6 9.0 V

Logic Signal Description Min Typ Max Unit

Gate Output Voltage Low -9 -10 -12 V

Gate Output Voltage High +14 +15 +16 V

Switching Frequency Note 2 3 15 kHz

IGBT Short Protection Description Min Typ Max Unit

Desat Monitor Voltage Between Collector and Emitter of IGBT 9 V

TDSAT* Activation after IGBT Turn on 6.1 μs

Response time after Fault 450 500 ns

Note 1: Input signal should not be activated until 20 ms after power is applied to allow on board DC-DC converter to stabilize.

Note 2: Actual maximum switching speed is a function of gate capacitance.

Note 3: Supply Current with load of 1.0 Ω and 180nF CINPUT + 6,000nC dynamic gate charge at an operating frequency of 5 kHz.



Interconnects

Controller/Power to Driver Connectors - Standard

Connector Type Manufacturer Part Number

Mating Ribbon Cable 4 Pin TE Connectivity 104257-3

Driver Board 4 Pin TE Connectivity 5-103635-3

Controller/Power to Driver Connectors (Optional - Please specify if required. Replaces Standard)


Mating Ribbon Cable 4 Pin ERNI 224398

Driver Board 4 Pin ERNI 214012

Cable Assemblies Cable ERNI 839016 (100 mm, terminated at both ends)

Contact ERNI for custom cable length

PINOUT

Pin No Signal

1 GND

2 VCC – +15V Supply Voltage

3 VCC – +15V Supply Voltage

4 GND

Recommended Interface Circuitry Power to Driver Connectors

ERNI Cable and Connector Ordering Information

North America, Canada and

Mexico

ERNI Electronics, Inc.

2201 Westwood Ave

Richmond, VA 23230

USA

Tel. +1 804 228-4100

[email protected]

Europe, South America, Africa,

Russia, and Japan

ERNI Electronics GmbH

Seestrasse 9

73099 Adelberg

Germany

Tel. +49 7166 50-0

[email protected]

Asia (excluding Japan)

ERNI Asia Holding Pte Ltd.

Blk 4008 Ang Mo Kio Avenue 10

#04-01/02 Techplace I

Singapore 569625

Tel. +65 6555 5885

[email protected]

Figure 4: HPFM Power Connecter 4-Pin

mailto:[email protected]





Interconnects (Continued)

Controller to Driver Connectors


Fiber Cable Fiber Avago HFBR-4516Z

Driver Board Transmit Fiber Avago HFBR-1522ETZ

Driver Board Receive Fiber Avago HFBR-2522ETZ

Master to Slave Connectors (Optional – Please specify if required, otherwise not populated)


Ribbon Cable 5 Pin TE Connectivity 5-103635-4

Driver Board 5 Pin TE Connectivity 104257-4



Timing Diagrams

Figure 5: Signal input and output timing diagram

Figure 6: Signal fault timing diagram for Desat.

Note: Application of the Fiber Input to low (LED Off) will clear the Fault signal. If a Desat condition reoccurs the Status/Fault signal

will go low again.

Figure 7: Signal fault timing diagram for UVLO.

Note: Status/Fault Signal will remain low until +V isolated is above specified voltage range of the UVLO Fault. Gate Drive Signal will

continue to occur until +V isolated falls below specified voltage range of UVLO Shut Down.



Timing Diagram Values

Conditions: VCC = +15.0 V, Temp = -40 ºC to 85 ºC, RgON = 1.5 Ω, RgOFF = 3.0 Ω

Description Symbol Min Typ Max Units Notes

Minimum Pulse Width TMIN 3000 ns

Delay Time TD 420 450 480 ns

Soft Turn Off Time TS 400 450 500 ns

Rise Time (no load) TR 50 60 ns Measured from 0V to 10V at RgON

Rise Time (with load) TR 600 650 ns Measured from 0V to 10V at RgON. Timing

will vary based on IGBT selection

Fall Time (no load) TF 30 60 ns Measured from Vsoft to 0V at RgOFF

Fall Time (with load) TF 350 400 ns Measured from Vsoft to 0V at RgOFF. Timing

will vary based on IGBT selection

Fiber Input (LED On)

to Status Ack (LED

Off) Delay

T1 700 800 ns Measured directly from Fiber Input receiver

midpoint to Status Ack (LED Off)

Gate Drive On to

Status Ack (LED On)

Delay

T2 700 750 800 ns Measured from Gate Drive (Vth) to Status

Ack (LED On)

Soft Turn Off to Status

Ack (LED Off) Delay

T3 150 200 ns Measured from beginning of Vsoft to Status

Ack (LED Off).

Fiber Input (LED On)

to Status Ack (LED

On) Delay

T4 2250 2500 2750 ns Measured directly from Fiber Input receiver

(LED On) midpoint to Status Ack (LED On)

Gate Drive Off to

Status Ack (LED On)

Delay

T5 400 500 600 ns Measured from Gate Drive at 0V to top of

Status Ack (LED On)

Fiber Input (LED Off)

to Status Ack (LED

On) Delay

T6 2600 2700 2800 ns Measured directly from Fiber Input receiver

midpoint to Status Ack (LED On).

Under Voltage Output

Delay Time

T7 1000 1500 ns

Status Acknowledge

Signal Width (Gate

Drive On)

T8 1650 1850 2050 ns Measured at midpoints. Actual width of the

Acknowledge Signal (LED OFF) is a

function of the actual gate capacitance of the

HPM IGBT (gate drive rise and fall times).

Status Acknowledge

Signal Width (Gate

Drive Off)

T9 1900 2100 2300 ns Measured at midpoints. Actual width of the

Acknowledge Signal (LED OFF) is a

function of the actual gate capacitance of the

HPM IGBT (gate drive rise and fall times).

Desaturation Time TDSAT 5700 6100 6300 ns Variable dependent on resistor value

Desaturation Fault

Status Delay Time

TFLT 250 300 ns



Description of Features

Two-Level Turn-Off (2LTO)/ Soft Shut Down (SSD)

The AgileSwitch HPFM gate driver uses the 2LTO/SSD mechanism to control Vce overshoot. It is used as a

standard feature during normal operation as well as during a short circuit events, when the IGBT can be stressed

by the high current and voltage. The Over-Voltage is a result of the stray inductance in the system and is

characterized by the equation:

𝑉 = −𝐿 ∗ (−𝑑𝑖

𝑑𝑡)

Where, V = Voltage Overshoot, L = Stray Inductance, di/dt = rate of change of current in the IGBT

1) AgileSwitch uses the 2LTO feature to control Vce overshoot in all conditions, thereby eliminating the

need for a large turn-off gate resistance, RgOFF

a. The mechanism of the 2LTO is, as the name suggests, turning off the power device in 2 stages

i. Stage I: The gate is forced to a pre-set VSOFT & is held there for tS

ii. Stage II: The gate is forced to VLOW

b. VSOFT & tS are configurable

2) The 2LTO time (tS) dictates the minimum allowable turn-on time. Figure 7 shows a timing diagram with

varying lengths of on-time, the effect being if the IGBT on-time is shorter than the 2LTO time, the gate

signal remains low. This is done to avoid shoot-through events.

Figure 8: Effect of 2 Level Turn-off time on minimum on-time definitions



With 2LTO Without 2LTO

Figure A

Figure B

Table 1 Waveforms to compare performance of AgileSwitch Gate Driver Board with 2LTO and without 2LTO (IGBT Used for Tests = 1200V, 450A)

Figures A (with 2LTO) B (without 2LTO) compares normal operation at Vdc = 600V, Ic = 450A. As is clear, The Vce

overshoot is ~120V lower when 2LTO is activated.



Desaturation Detection (Short Circuit Protection)

The AgileSwitch Gate Driver Board protects the IGBT against short circuit by way of desaturation detection.

The IGBT Collector-Emitter Voltage (Vce) is monitored at turn-on and during operation, if a short circuit occurs,

Vce increases (IGBT de-saturates) and the fault is triggered.

The AgileSwitch Gate Driver Board has a desaturation detection circuit with a configurable voltage threshold and

blanking time. In a short circuit event, the Vce saturation voltage increases and when this reaches the preset

threshold the circuit is activated and a fault is sent to the host.

Note: CH1 = Fiber optic input (Drive Signal); CH2 = Fiber optic output (Status Feedback), CH3 = Gate voltage on HPFM

Figure 11 below is an example of a de-sat condition with Vdc = 160V as current reaches 1600A when desat is

detected.

Figure 11 DSAT Fault Condition – Vdc = 160V, Ic = 1600A

Figure 10: DSAT Fault Condition (left) and DSAT timing (TDSAT) (right).

Note:

CH 2: Vge (5 V/Div),

CH 3: Ice (1000 A/Div)

Noise in the waveform is

a result of the Test set-up

DSAT Detected



Figure C

Figure D

Table 2 Waveforms to compare Short Circuit with 2LTO and without 2LTO (IGBT Used for Tests = 1200V, 450A)

Figures C (with 2LTO) Figure D (without 2LTO) compares a short circuit condition at Vdc = 600V, Ic ~1500A.

Without 2LTO in Figure D, Active Clamping has kicked in due to large Vce overshoot (~200V) and Vge

oscillation.

In Figure C the 2LTO controls the Vce overshoot as well as Vge oscillation.



Active Clamping

AgileSwitch Gate Drivers use active clamping as a secondary fail safe to the 2LTO mechanism. The

implementation is fairly straightforward with TVS diodes. However, with the 2LTO implemented for all switching

cycles, the need for the active clamping is reduced to otherwise catastrophic events.

Figure 12 Example of Active Clamping Circuit

With 2LTO Without 2LTO

Figure C

Figure D

Table 3 Waveforms to compare Active Clamping with 2LTO and without 2LTO (IGBT Used for Tests = 1200V, 450A)

Figures E (with 2LTO) and F (without 2LTO) compares an Active Clamping condition. As in both cases Active Clamping

has kicked in, the advantage of the 2LTO mechanism is in suppressing oscillations and voltage spikes in the gate line.The

IGBT gate is very sensitive and many of the IGBT manufacturers limit the maximum gate voltage to 20V, this has been

controlled with 2LTO enabled.



Under Voltage Lockout (UVLO)

The input supply voltage range for the AgileSwitch HPFM Gate Drive Board is +14.5V to +16V. By default the

UVLO detect level is set to +12.8V, but can be modified based on the end user requirement. If the IGBT voltage

drops below this value, there may be failures due to difficulty in control and hence it is important to monitor the

input supply voltage.

Input and Output pins of the HPFM Gate Driver Board

Figure 10 below describes the connections on the AgileSwitch HPFM Gate Driver Board.

Figure 12

Generic Sample Factory Settings

1. The default equivalent gate resistance for the driver is 1.5 Ω (RgON), 1.5 Ω (RgOFF). This is a safe value for

all supported IGBT modules. For optimum performance, the equivalent gate resistance may be changed from

3.0 Ω up to 10.0 Ω.

2. Desaturation (TDSAT) monitoring is set for 6.1 µs. This can be adjusted from 1 through 10 µs. The voltage

level can be configured to any whole number value between 7V to 13V. The default setting is 9V. If the

voltage across the IGBT is greater than the set voltage level, a desaturation fault is detected and the IGBT is

turned off and a fault signal is output. Please contact AgileSwitch for requested desaturation monitor time and

voltage.

Serial Number

Collector Emitter Gate

Power Connector Slave Connector Fiber Receiver Fiber Transmitter



Generic Sample Factory Settings – Fault and Monitoring Conditions

AgileSwitch drivers are designed to provide safe, secure and efficient operation of the IGBT as well as to provide

unparalleled information on the condition of the overall system.

Generic samples are set at the factory to perform certain actions and to report that a fault occurred based on IGBT

performance parameters that occur outside of default ranges. Certain parameters are configurable. Please contact

AgileSwitch for details.

Fault

Condition/Action

Generic Sample Default

Trigger Values

Action on IGBT (if

Active)

Lockout Fiber

Output for

Fault

UVLO Fault See Electrical Characteristics None No Light Off

UVLO Shut down See Electrical Characteristics Turn Off Yes Light Off

DSAT See Electrical Characteristics Turn Off No Light Off

Active Clamping 950V1 (1200V IGBT)

1350V1 (1700V IGBT)

2500V1 (3300V IGBT)

Active Clamping

Occurs

No

1 Configurable parameter

Fault/Status Reporting Information

When a UVLO or desaturation fault occurs, the fiber output status feedback is light off. The host controller will

attempt to trigger the device when a fault occurs. If the fault clears, it was a DSAT, if it does not clear, it is a

UVLO. The driver will perform normal triggering once the UVLO fault clears or is cleared. The UVLO fault

does not need a trigger to clear.

Fiber Connectors-Logic

Fiber Direction Light On Light Off

Input (Drive Signal) On Command Off Command

Output (Status Feedback) No Fault Fault

Note: Please refer to timing diagrams on Page 10 for graphical representation

http://www.agileswitch.com/Contact-us.page



Revisions

Prepared By Approved By Version Date Description

N. Satheesh 01 08/31/2015 Preliminary release

N. Satheesh 02 10/07/2015 Added information and waveforms for protection

features



Legal Disclaimer

Information in this document is provided solely in connection with AGILESWITCH products. AGILESWITCH, LLC and its subsidiaries

(“AGILESWITCH”) reserve the right to make changes, corrections, modifications or improvements, to this document, and the products

and services described herein at any time, without notice.

All AGILESWITCH products are sold pursuant to AGILESWITCH’s terms and conditions of sale.

Purchasers are solely responsible for the choice, selection and use of AGILESWITCH products and services described herein, and

AGILESWITCH assumes no liability whatsoever relating to the choice, selection or use of the AGILESWITCH products and services

described herein.

No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. If any part of

this document refers to any third party products or services it shall not be deemed a license grant by AGILESWITCH for the use of such

third party products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner

whatsoever of such third party products or services or any intellectual property contained therein.

UNLESS OTHERWISE SET FORTH IN AGILESWITCH’S TERMS AND CONDITIONS OF SALE AGILESWITCH DISCLAIMS

ANY EXPRESS OR IMPLIED WARRANTY WITH RESPECT TO THE USE AND/OR SALE OF AGILESWITCH PRODUCTS

INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR

PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION), OR INFRINGEMENT OF ANY

PATENT, COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT.

UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED AGILESWITCH REPRESENTATIVE, AGILESWITCH

PRODUCTS ARE NOT RECOMMENDED, AUTHORIZED OR WARRANTED FOR USE IN MILITARY, AIR CRAFT, SPACE,

LIFE SAVING, OR LIFE SUSTAINING APPLICATIONS, NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR

MALFUNCTION MAY RESULT IN PERSONAL INJURY, DEATH, OR SEVERE PROPERTY OR ENVIRONMENTAL DAMAGE.

AGILESWITCH PRODUCTS WHICH ARE NOT SPECIFIED AS "AUTOMOTIVE GRADE" MAY ONLY BE USED IN

AUTOMOTIVE APPLICATIONS AT USER’S OWN RISK.

Resale of AGILESWITCH products with provisions different from the statements and/or technical features set forth in this document

shall immediately void any warranty granted by AGILESWITCH for the AGILESWITCH product or service described herein and shall

not create or extend in any manner whatsoever, any liability of AGILESWITCH.

AGILESWITCH, the AGILESWITCH logo, AgileStack, AgileStack Communications and Stack Black Box are trademarks or registered

trademarks of AGILESWITCH, LLC in various countries. Any other names are the property of their respective owners.

Information in this document supersedes and replaces all information previously supplied.

Specifications are subject to change without notice.

© 2010-2015 AGILESWITCH LLC - All rights reserved www.AgileSwitch.com.

Patent Notices Offering Issued U.S. Patent Numbers

AgileStackTM Power Stack 8,984,197

Manufacturer AgileSwitch, LLC Tel: +1-484-483-3256 (US)

1650 Arch Street, #1905 +44 (0)1273 252994 (Europe)

Philadelphia, PA 19103 +86 (10) 60539835 (China)

United States Email: [email protected]

Web: www.AgileSwitch.com

http://dl.dropbox.com/u/18470390/AgileSwitch%20Terms%20and%20Conditions%20of%20Sale.pdf

http://www.agileswitch.com/

http://www.agileswitch.com/

agileswitch gate drivers hpfm-hpm fiber series user manual

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