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IGBT POWER MODULE FOR INVERTER/CHOPPER

(Model No : VPET - 106A)

User Manual

Version 1.0

Technical Clarification /Suggestion : N/F Technical Support Division,

Vi Microsystems Pvt. Ltd.,


Plot No :75,Electronics Estate, Perungudi,Chennai - 600 096,INDIA. Ph: 91- 44-2496 3142, 91-44-2496 1852, Mail : service@vimicrosystems.com, Web : www.vimicrosystems.com

CONTENTS
1. INTRODUCTION 2. FUNCTIONAL DESCRIPTION 3. THEORETICAL DESCRIPTION 4. STUDY OF CONTROLLER 5. INSTALLATION AND OPERATION 6. EXPERIMENTAL SECTION i. STUDY OF THE PROCESS ii. STUDY OF OPEN LOOP RESPONSE iii. STUDY OF CLOSED LOOP RESPONSE iv. TIME RESPONSE OF SECOND ORDER SYSTEM WITH P CONTROL v. TIME RESPONSE OF SECOND ORDER SYSTEM WITH P+I CONTROL vi. TIME RESPONSE OF SECOND ORDER SYSTEM WITH P+I+D CONTROL vii. EFFECT OF DISTURBANCES ON A PROCESS 7. CIRCUIT DIAGRAM 1 2 14 20 23 26 26 28 30

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IGBT Power Module for Inverter / Chopper

VPET-106A

Chapter-1

Introduction

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IGBT Power Module for Inverter / Chopper Aim

VPET-106A

This manual is intended to give you a description of IGBT Power Module for Inverter/chopper (VPET-106A) trainer module followed by the working procedure involved with our trainer module. Objectives On successful completion of this manual you should be able to : * * * Understand about the IGBT Power Module for Inverter/chopper . Describe the Sinusoidal Pulse Width Modulation. Can be able to work with our module by yourself.

Features of VPET-106A * PWM signals can be generated from any one of the various PWM controllers like Microprocessors, Microcontrollers, DSP, dsPIC, FPGA, etc., The module can be used to study the operation of both the inverter and chopper circuit. Test points are provided on the front panel to view the signals at the various stages of operation. Study of various modulation techniques and study of inverter/chopper circuits can be done by this module. The PWM isolation, gate driver section and signal conditioning circuits are provided in the module. DC rail voltage can be directly read from the voltmeter provided in the module.

* *

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IGBT Power Module for Inverter / Chopper 1.1 Introduction

VPET-106A

Power Electronics is a subject that concerns with the application of electronic principles into situations that are rated at power level rather than signal level. For example, semiconductor power switches such as thyristors, GTOs, MOSFETs, IGBTs work on the principle of electronics (movement of holes and electrons), but have the name power attached to them only as a description of their power ratings. Power Electronics are employed in various fields that include rocket propulsion systems, motor control, Electric vehicles, air-conditioners, High Voltage Direct Current (HVDC) transmission systems. Power Electronics System A power electronic system consists of one or more power electronic converters. A power electronic converter is made up of some power semiconductor devices controlled by integrated circuits. The switching characteristics of power semiconductor devices permit a power electronic converter to shape the input power of one form to output power of some other form. Types of Power Electronics system Diode Rectifiers : A diode rectifier circuit converts ac input voltage into a fixed DC voltage. These convert constant AC voltage to variable DC output voltage. A DC chopper converts fixed DC input voltage to a controllable DC output voltage. An inverter converts fixed DC voltage to a variable AC voltage. These convert fixed AC input voltage into variable AC output voltage.

AC to DC converters

DC to DC converters

DC to AC converters

AC to AC converters

This manual describes the IGBT POWER MODULE FOR INVERTER/CHOPPER operation

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IGBT Power Module for Inverter / Chopper

VPET-106A

Chapter-2

About Our Trainer

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IGBT Power Module for Inverter / Chopper 2.1 Front Panel View

VPET-106A

1. VPET-106A

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IGBT Power Module for Inverter / Chopper 2.2 Front Panel Description To switch ON/OFF power to the module.

VPET-106A

Power ON/OFF switch MCB PWM INPUT

To control input AC voltage to the power circuit. To connect the PWM input / feedback signal from / to the controller unit. To connect 3? output to the load. To display DC link voltage. To connect AC input to the module. To connect the DC output to the load. To reset the module. Test points to view the PWM signal to the switches with respect to ground point. Test points to view the sensed input DC current & output R, Y and B phase currents. To isolate the gate signals.

R, Y, B Voltmeter P, N A+, A-, F+, (+) RST PWM1, PWM 2...PWM 6

Idc, Ir, Iy, Ib

PWM Isolation

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IGBT Power Module for Inverter / Chopper 2.3 Hardware Description

VPET-106A

2.3.1 Block Diagram

Idc P ??? C N
+ -

3 LEG MOSFET/ IGBT DEVICE MODULE

Ir Iy Ib AC/DC O/P

RECTIFIER

DRIVER

VPET-105A/106A MODULE OPTO-ISOLATIOR

CURRENT SENSOR SIGNALS FROM POWER CIRCUIT

Idc Ir Iy Ib

SIGNAL CONDITIONER

PWM CONTROLLER

The block diagram for IGBT power module consists of the following. 1. 2. 3. 4. 5. 6. 7. 8. Rectifier & Filter Power circuit Controller Optoisolator Gate Driver Current Sensor Signal conditioner Protection Circuit.

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IGBT Power Module for Inverter / Chopper 2.3.2 Block Diagram Description 1. Rectifier & Filter

VPET-106A

The input AC voltage is rectified by the Diode Bridge Rectifier circuit. The rectified DC voltage is fed to the power circuit through a filter capacitor. The filter capacitor eliminates the unwanted ripple in the Dc input. 2. Power Circuit The Power circuit consists of three leg IGBT circuit. IGBT switch is used as a switching device in the power circuit. The PWM signal from the driver IC is fed to the gate of the switch. The output from the power circuit is given to the load. The output may be either AC/DC depending on the inverter/chopper mode of operation. 3. Controller The PWM signal to the IGBT switches are generated by the controller unit. The controller may be any processor. The PWM signal from the controller is fed to the module through the connector provided on the front panel. In this implementation, controller is used PWM generation. 4. Optoisolator (6N137) The function of Optoisolator is to isolate the control circuit from power circuit. PWM signal from the controller is not directly fed to the power circuit in order to protect the PWM signal it is essential to provide isolation circuit between power circuit and control circuit or else the high power components may damage the low power PWM circuit components. 5. Gate Driver (IR2110) A IGBT drive circuit is designed to connect the gate directly to a voltage bus with no intervening resistance other than the impedance of the drive circuit switch. Gate driver acts as a high-power buffer stage between the PWM output of the control device and gates of the primary power switching IGBT.

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IGBT Power Module for Inverter / Chopper 6. Current Sensor

VPET-106A

IGBT power module output current is not directly fed to control (Protection) circuits. The sensor used for sensing current works on the principle of hall effect. Hence these sensors are called hall effect transducer. Hall effect transducer output current depends upon transducer primary and secondary winding ratio. The turns ratio represents the ratio of the number of primary turns to the number of secondary turns. A Hall effect current transducer senses the current IDC, Ir(R), Iy(Y) Ib(B).
FROM OUTPUT From 1F Diode Bridge Rectifier IDC

Hall-Effect Current Transducer (CT1)

Hall-Effect Current Transducer (CT2)

Hall-Effect Current Transducer (CT3)

Hall-Effect Current Transducer (CT4)

Idc

Ir

Iy

Ib

Current Transducer 7. Signal Conditioner The signal from the current sensor is fed back to the controller unit. The gain of the current signals has to be improved to achieve controller requirements. So the signal needs to be conditioned in the signal conditioner circuits.

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IGBT Power Module for Inverter / Chopper

VPET-106A

Idc

Non-inverting Amplifier

Inverting Amplifier

Comparator
5V

dsPIC.CT.IN

IDC Offset Voltage Gain (TR1)

IDC Gain (TR1)

Reference Voltage

Active Filter

AF OUT Ir

Ir
R-Phase
Offset Voltage

Non-Inverting Amplifier

Non-Inverting Amplifier

From Current Sensor

(TR3) R-Phase Gain (TR2)

Iy
Y-Phase Offset Voltage (TR5)

Non-Inverting Amplifier

Non-Inverting Amplifier

Iy To dsPIC

Y-Phase Gain (TR3)

Ib
B-Phase Offset Voltage

Non-Inverting Amplifier

Non-Inverting Amplifier

Ib

(TR7) B-Phase Gain (TR4)

Signal Conditioner 8. Protection Circuit In the protection circuit the DC current I dc is sensed. If the I dc value increases than the limit, the protection circuit activates and cuts the PWM to the switches in the module. The LED glows to indicate the system shut down condition. The system can be reset by the RST press button provided on the front panel. Now the LED switches OFF. Again the PWM signal should be applied to the system. Note: The sensing and conditioning of the output current is an optional future of ths module and it is of additional cost to the module.

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IGBT Power Module for Inverter / Chopper 2.4 Datasheets

VPET-106A

1. IGBT SWITCH

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IGBT Power Module for Inverter / Chopper

VPET-106A

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IGBT Power Module for Inverter / Chopper

VPET-106A

Vi Microsystems Pvt. Ltd.,

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IGBT Power Module for Inverter / Chopper 2. 6N137

VPET-106A

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IGBT Power Module for Inverter / Chopper 3. IR2110

VPET-106A

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IGBT Power Module for Inverter / Chopper 2.5 Protection 1. Fuse is provided to protect the module from over current fault. 2. RC Snubber circuit is provided in each device to protect IGBTs. Protection and Precaution

VPET-106A

3. MCB is provided to protect the power circuit in case of single phase AC input over voltage fault. 4. Protection circuit is provided to shut down the PWM signal to the switches at fault condition with LED indication. Precaution 1. Before doing connection make all switches in OFF position. 2. Do not switch OFF IGBT power module when unit is working. 3. Do not view the input waveform and pulse waveform with CRO in dual mode. 4. Dont short output R, Y, B terminals. 5. Dont remove the PWM pulse cable when unit is in operation.

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IGBT Power Module for Inverter / Chopper

VPET-106A

Chapter-3

Theoretical Concept
(This section is solely to explain the theoretical details of IGBT Power Module for Inverter / Chopper (VPET-106A) by considering the ideal conditions which may vary for practical conditions. So some difference may be seen between the ideal responses to the practical responses of our trainer.)

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IGBT Power Module for Inverter / Chopper

VPET-106A

The following section discusses about the three phase inverter and four quadrant chopper circuit operation. 3.1 Inverter

Inverter is a static power converter whose objective is to produce an AC output waveform from a DC power supply. These are required in adjustable speed drives, uninterruptible power supplies, FACTS (Flexible AC transmission systems), voltage compensators etc. For sinusoidal AC output, the magnitude, phase and frequency should be controllable. A 3? Inverter is explained. 3.1.1 Three Phase Inverter Operation In application such as uninterruptible AC power supplies and ac motor drives, three phase inverters are commonly used to supply three-phase loads. The most frequently used three-phase inverter circuit consists of three-legs, one for each phase. Each leg consists of 2 IGBTs so totally this circuit uses six IGBTs. For one cycle of 360, each step would be of 60 interval for a sixstep inverter. This means that IGBTs would be gated at regular intervals of 60 in proper sequence so that a three-phase AC voltage is synthesized at the output terminal of a six-step inverter.

T1

D1

T3

D3

T5

D5

V s

+ -

+ T4 D2 T6 D6 T2 D2

V ca Vab

b 3? Load

Vbc

Basically, there are two possible modes of gating the IGBT . They are, * * 180 mode 120 mode Each IGBT conducts for 180 Each IGBT conducts for 120

But in both these schemes, gating signals are applied and removed at 60 intervals of the output voltage waveform. Therefore, both these modes require a six-step bridge inverter.

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IGBT Power Module for Inverter / Chopper 3.1.2 Three - Phase 180 Conduction Mode

VPET-106A

In this scheme, called the 180 mode of operation, a maximum of three IGBTs conduct at any instant and each IGBT conducts for ? radians in every cycle of the output. Switch pair in each leg, i.e. T1- T4, T3- T 6 and T2- T5 are turned-ON with a time interval of 180. Same is true for lower group of IGBT. On the basis of this firing scheme, table is prepared. It is observed from table that in every step of 60 duration, only three IGBTs are conducting - two from upper group and one from the lower group and vice versa. INTERVAL I II III IV V VI IGBTs CONDUCTING T1, T6, T5 T1, T6, T2 T1, T3, T2 T2, T3, T4 T3, T5,T4 T4, T5, T6

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IGBT Power Module for Inverter / Chopper

VPET-106A

Gate current signals and output voltage waveforms for three phase inverter is shown below.
I g1

0 Ig 2 0 I g3 0 Ig4 0 I g5 0 Ig6 0 V an
Vdc 3

2? 3

?? 3

?? 3

2?

Intervals
Vbn

0 I

2Vdc 3 II

III

IV

VI

t 2? 3? 4?

0
-2V dc 3

2Vdc 3

Vcn 0
-2V dc 3

2Vdc 3

V AB Vdc 0 VBC Vdc 0 -V dc VCA 0 ? 2? 3? 4? t -V dc t

The switching sequence is controlled by the PWM technique. The PWM technique implemented in this module is sinusoidal pulse width modulation.

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IGBT Power Module for Inverter / Chopper Sinusoidal Pulse Width Modulation

VPET-106A

The switching sequence for the inverter switches in this case, is obtained by comparing a sinusoidal control signal, of adjustable amplitude and frequency with a fixed frequency triangular carrier. The frequency of the triangular carrier wave determines the switching frequency (fs) of the inverter switches. The frequency (f1) of the sinusoidal control signal decides the fundamental frequency of the inverter output voltage, and is also called the modulating frequency. The inverter output voltage will contain voltage components at harmonic frequencies of f1. The amplitude modulation ratio ma also called the modulation index is defined as

Where Vcontrol is the amplitude of the control signal and Vtri is amplitude of the triangular carrier, which is generally kept constant. The sinusoidal pulse width modulated wave is shown below.

Sinusoidal Pulse-Width Modulation The output voltage of the inverter is given by,

VO ? ma ? Vin
where, Vo ma V in = = = output voltage , volts. modulation index. input DC voltage , volts.

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IGBT Power Module for Inverter / Chopper 3.2 Chopper

VPET-106A

In AC application, the transformer serves to convert electric power efficiently from one voltage level to another. Static DC to DC converters called as choppers achieve a similar function in DC. The operation of AC transformer is based on an alternating magnetic field. But in chopper the voltage conversion is achieved by power semiconductors, which function as static switches, switching at high repetitive frequency. Choppers are widely used for traction motor control, in electric automobiles, trolley cars, marine hoists, fork lift trucks, and mine haulers. They provide smooth acceleration control. high efficiency, and fast dynamic response. This module uses four quadrant chopper with R-L Load for DC-DC conversion. The four quadrant chopper is explained below. Four Quadrant Chopper In four quadrant operation the output current as well as output voltage can take positive or negative values. The circuit diagram for IGBT based chopper is shown below.

T1

D1 L R

T3 E
+ -

D3

V s

+ T4 D4

T2

D2

Four quadrant chopper circuit. In the first quadrant the power flows from the source to the load and is assumed to be (+)ve. In the second quadrant the voltage is still positive but the current is negative. The power is therefore negative. In this case power flows from the load to the source and this can happen if the load is inductive or back emf source such as a dc motor. In the third quadrant both the voltage and current are negative, but the power is positive, and the power flows from the source to the load. In the fourth quadrant voltage is negative but the current is positive. The power is therefore negative. The four quadrant chopper is widely used in reversible dc motor drives. The reversible dc motor drive system requires, power flow in either direction, in order to achieve fast dynamic response. By employing four quadrant chopper it is possible to implement regeneration and dynamic braking by means of which fast dynamic response is achieved.

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IGBT Power Module for Inverter / Chopper Circuit Operation Quadrant I Conducting Switches T1 & T4 Mode Forward Motoring/ Rectifying

VPET-106A

Description Load consumes power from the source io & Vo both are positive. Load current flow is maintained by inductor and free wheeling diode .io & Vo both are positive. Load energy is fed to the supply. io - positive. Vo - negative io & Vo both are positive. io & Vo both are positive. Energy is fed to the supply. io - negative Vo - positive.

II

T4 & D2

Forward Motoring/ Free wheeling operation

IV

D3 & D2

Inverting

III

T3 & T2

Rectifying, current flow is in opposite direction Free wheeling operation Inverting Operation

III I

T2 & D4 D1 & D4

Four Quadrant Chopper Operation


V o II Quadrant Regeneration -i o III Quadrant Power Positive -V o IV Quadrant Regeneration I Quadrant Power Positive io

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