Infineon REF-22K-GPD-INV-EASY3B User Manual
User Guide Please read the Important notice and the Safety precautions and the Warnings
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UG-2020-28
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
About this document
Scope and purpose
This user guide provides an overview of the evaluation kit REF-22K-GPD-INV-EASY3B including its main
features, key data, pin assignments, mechanical dimensions and corresponding control card. The reference kit
REF-22K-GPD-INV-EASY3B is an industrial motor drive for three-phase 400 V AC grids and has a nominal power
of 22 kW.
The REF-22K-GPD-INV-EASY3B includes the Easy3B power module FP100R12W3T7_B11, the current sensor
TLI4971-A120T5, the gate driver IC 1ED3131MC12H, the 1.7 kV SiC-MOSFET IMBF170R1K0M1 and the
microcontrollers XMC4800-F144F2048 and XMC4300-F100K256. The combination of these Infineon products
allows the customer to evaluate these products in one design and experience the interaction between the
products.
Beside the hardware, the REF-22K-GPD-INV-EASY3B offers you software for control and communication. The
inverter can be controlled via a touch screen and PC-GUI.
Note: Please note that this product is not qualified according to the AEC Q100 or AEC Q101 documents of
the Automotive Electronics Council.
Intended audience
This user guide is intended for all technical specialists working on industrial drives and those interested in how
the latest Infineon products like IGBT7, XENSIV™ current sensors, EICE™ drivers and CoolSiC™ MOSFETs perform
under application conditions.
Reference Kit
The Infineon products are embedded on this PCB with functions and form factor close to a commercial design.
PCB and auxiliary circuits are optimized for the final design.
Note: Boards do not necessarily meet safety, EMI, quality standards (for example UL, CE) requirements.
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User Guide for REF-22K-GPD-INV-EASY3B
Reference design for motor general purpose drives
The reference board at a glance
Important notice
“Evaluation Boards and Reference Boards” shall mean products embedded on a printed circuit board
(PCB) for demonstration and/or evaluation purposes, which include, without limitation, demonstration,
reference and evaluation boards, kits and design (collectively referred to as “Reference Board”).
Environmental conditions have been considered in the design of the Evaluation Boards and Reference
Boards provided by Infineon Technologies. The design of the Evaluation Boards and Reference Boards
has been tested by Infineon Technologies only as described in this document. The design is not qualified
in terms of safety requirements, manufacturing and operation over the entire operating temperature
range or lifetime.
The Evaluation Boards and Reference Boards provided by Infineon Technologies are subject to functional
testing only under typical load conditions. Evaluation Boards and Reference Boards are not subject to the
same procedures as regular products regarding returned material analysis (RMA), process change
notification (PCN) and product discontinuation (PD).
Evaluation Boards and Reference Boards are not commercialized products, and are solely intended for
evaluation and testing purposes. In particular, they shall not be used for reliability testing or production.
The Evaluation Boards and Reference Boards may therefore not comply with CE or similar standards
(including but not limited to the EMC Directive 2004/EC/108 and the EMC Act) and may not fulfill other
requirements of the country in which they are operated by the customer. The customer shall ensure that
all Evaluation Boards and Reference Boards will be handled in a way which is compliant with the relevant
requirements and standards of the country in which they are operated.
The Evaluation Boards and Reference Boards as well as the information provided in this document are
addressed only to qualified and skilled technical staff, for laboratory usage, and shall be used and
managed according to the terms and conditions set forth in this document and in other related
documentation supplied with the respective Evaluation Board or Reference Board.
It is the responsibility of the customer’s technical departments to evaluate the suitability of the
Evaluation Boards and Reference Boards for the intended application, and to evaluate the completeness
and correctness of the information provided in this document with respect to such application.
The customer is obliged to ensure that the use of the Evaluation Boards and Reference Boards does not
cause any harm to persons or third party property.
The Evaluation Boards and Reference Boards and any information in this document is provided "as is"
and Infineon Technologies disclaims any warranties, express or implied, including but not limited to
warranties of non-infringement of third party rights and implied warranties of fitness for any purpose, or
for merchantability.
Infineon Technologies shall not be responsible for any damages resulting from the use of the Evaluation
Boards and Reference Boards and/or from any information provided in this document. The customer is
obliged to defend, indemnify and hold Infineon Technologies harmless from and against any claims or
damages arising out of or resulting from any use thereof.
Infineon Technologies reserves the right to modify this document and/or any information provided
herein at any time without further notice.
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User Guide for REF-22K-GPD-INV-EASY3B
Reference design for motor general purpose drives
The reference board at a glance
Safety precautions
Note: Please note the following warnings regarding the hazards associated with development systems.
Table 1 Safety precautions
Warning: The DC link potential of this board is up to 1000 VDC. When measuring
voltage waveforms by oscilloscope, high voltage differential probes must be used.
Failure to do so may result in personal injury or death.
Warning: The evaluation or reference board contains DC bus capacitors which take
time to discharge after removal of the main supply. Before working on the drive
system, wait five minutes for capacitors to discharge to safe voltage levels. Failure to
do so may result in personal injury or death. Darkened display LEDs are not an
indication that capacitors have discharged to safe voltage levels.
Warning: The evaluation or reference board is connected to the grid input during
testing. Hence, high-voltage differential probes must be used when measuring voltage
waveforms by oscilloscope. Failure to do so may result in personal injury or death.
Darkened display LEDs are not an indication that capacitors have discharged to safe
voltage levels.
Warning: Remove or disconnect power from the drive before you disconnect or
reconnect wires, or perform maintenance work. Wait five minutes after removing
power to discharge the bus capacitors. Do not attempt to service the drive until the bus
capacitors have discharged to zero. Failure to do so may result in personal injury or
death.
Caution: The heat sink and device surfaces of the evaluation or reference board may
become hot during testing. Hence, necessary precautions are required while handling
the board. Failure to comply may cause injury.
Caution: Only personnel familiar with the drive, power electronics and associated
machinery should plan, install, commission and subsequently service the system.
Failure to comply may result in personal injury and/or equipment damage.
Caution: The evaluation or reference board contains parts and assemblies sensitive to
electrostatic discharge (ESD). Electrostatic control precautions are required when
installing, testing, servicing or repairing the assembly. Component damage may result
if ESD control procedures are not followed. If you are not familiar with electrostatic
control procedures, refer to the applicable ESD protection handbooks and guidelines.
Caution: A drive that is incorrectly applied or installed can lead to component damage
or reduction in product lifetime. Wiring or application errors such as undersizing the
motor, supplying an incorrect or inadequate AC supply, or excessive ambient
temperatures may result in system malfunction.
Caution: The evaluation or reference board is shipped with packing materials that
need to be removed prior to installation. Failure to remove all packing materials that
are unnecessary for system installation may result in overheating or abnormal
operating conditions.
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User Guide for Ref_22k_GPD-INV_Easy3B
Reference design for motor general purpose drives
Table of contents
Table of contents
About this document ....................................................................................................................... 1
Important notice ............................................................................................................................ 2
Safety precautions .......................................................................................................................... 3
Table of contents ............................................................................................................................ 4
1 The reference board at a glance ............................................................................................... 5
1.1 Delivery content ...................................................................................................................................... 5
1.2 Block diagram .......................................................................................................................................... 5
1.3 Main features ........................................................................................................................................... 7
1.4 Board parameters and technical data .................................................................................................... 7
1.4.1 Overload profile normal duty ............................................................................................................ 8
1.4.2 Heavy duty overload profile .............................................................................................................. 9
2 System and functional description .......................................................................................... 10
2.1 Commissioning ...................................................................................................................................... 10
2.2 Description of the functional blocks ..................................................................................................... 14
2.2.1 Hardware partitioning ..................................................................................................................... 14
2.2.2 Isolation coordination ..................................................................................................................... 16
2.2.3 Board interconnection schemes ..................................................................................................... 17
2.2.4 Supply schemes ............................................................................................................................... 18
2.2.5 Component selection ....................................................................................................................... 18
3 System design....................................................................................................................... 19
3.1 Schematics ............................................................................................................................................ 19
3.2 Layout .................................................................................................................................................... 19
3.2.1 Power board ..................................................................................................................................... 19
3.3 Inverter cooling concept ....................................................................................................................... 21
3.4 Disassembly of the housing .................................................................................................................. 22
3.5 Bill of material ....................................................................................................................................... 25
3.6 Connector details .................................................................................................................................. 25
4 System performance ............................................................................................................. 28
4.1 Test results inverter start-up ................................................................................................................ 28
4.2 Operation under rated conditions ........................................................................................................ 29
4.3 Switching behavior of the IGBT turn-on ............................................................................................... 31
4.4 Switching behavior of the IGBT – turn-off ............................................................................................ 32
4.5 Thermal behavior of the inverter under high overload ....................................................................... 33
4.6 Short-circuit measurement ................................................................................................................... 34
5 References and appendices .................................................................................................... 36
5.1 Abbreviations and definitions ............................................................................................................... 36
5.2 References ............................................................................................................................................. 36
Revision history ............................................................................................................................. 37
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The reference board at a glance
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
1 The reference board at a glance
1.1 Delivery content
The reference kit is a general purpose drive developed for applications like pumps, fans, compressors,
conveyor belts. The design has the look and feel of a typical drive and includes EMI filter, pre-charge and
capacitor bank, isolated power supplies, power module, controls and heat sink with fan. It can be operated
directly on a three-phase grid, enabling a fast evaluation of Infineon's newest technologies like IGBT7, gate
driver, current sensor and control in one system. This enables the unique opportunity to see the improvement
by combining Infineon's newest technologies. You will see how the new IGBT7 modules work with the EICE™
gate driver, or test the accuracy of the current sensor.
1.2 Block diagram
The block diagram of the inverter REF-22K-GPD-INV-EASY3B is shown in Figure 1. The board consists of five
boards: power board, EMI filter, high-voltage logic board, low-voltage interface board, and the DC-link board
which are mounted in one housing. For more details see Section 2.2.1.
Figure 1 Block diagram of the inverter
The reference kit REF-22K-GPD-INV-EASY3B is a fully operation industrial drive inverter which can be connected
to a three-phase AC input supply. The reference kit includes an input EMI-filter. The AC voltage is rectified via
the uncontrolled diode full bridge. The inrush current is limited by pre-charge circuitry. The rectified AC voltage
is stabilized by a DC-link capacitor bank. The IGBT six pack allows for the modulation of a three-phase output
voltage/current which can be varied in terms of its amplitude and frequency. This three-phase current is used
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The reference board at a glance
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
for controlling the speed and torque of the motor. During braking or deceleration of the motor, energy is
transferred back into the DC-link capacitor increasing the DC bus voltage. Therefore, a brake chopper is
included that absorbs this energy by switching an external brake resistor across the DC bus capacitors. The
three-phase input rectifier, the six pack as well as the brake chopper are all included in one power module, the
Easy3B IGBT FP100R12W3T7_B11. All IGBTs are switched using EICE™ drivers, the 1ED3131MC12H. The isolation
coordination details of the unit can be found in Section 2.2.2.
The current measurement of the three-phase output current is done with TLI4971-A120T5 current sensors. The
current signals are used for the motor control; additionally, these sensors are used to detect an external short
circuit for the IGBT’s. To protect the module against an internal short circuit, a fourth current sensor is
integrated between the DC-link capacitor and the IGBT module.
The auxiliary voltage for the inverter is generated with a DC/DC switch mode power supply (SMPS) converter.
The CoolSiC™-MOSFET IMBF170R1K0M1 is used in a flyback topology. More details about the flyback SMPS are
listed in Section 2.2.4.
The reference inverter uses two microcontrollers; one for control and one for communication. For control the
XMC4800-F144F2048 is used, for communication the XMC4300-F100K256 AA is designed in. Both
microcontrollers communicate via an UART interface. The communication microcontroller allows the inverter
to be controlled via a touch-screen or a PC-GUI. More details on the communication interface can be found in
Section 2.2.1.
A simplified block diagram is shown in Figure 2. The block diagram shows the main components of the boards,
the DC/DC SMPS converter, the low-voltage interface board (SELV board), high-voltage logic board (FELV
board), the IGBT module incl. the gate driver IC, and the output phase current measurement. Also the main
Infineon components used in the specific blocks are listed in the diagram.
-_
high voltage
logic board
(FELV board)
low voltage
interface board
(SELV board)
rectifier
DC/DC converter
EMI filter
six pack
3Ph
Motor
user
interfaces
front
display
sensor
interfaces
3 phase
AC Input
3 phase
AC output
brake chopper
DC-Link
brake resistor
pre charge
resistor/relay
FP100R12W3T7_B11
1ED3131MC12H
curr
3 ph
TLI4971
IMBF170R1K0M1
XMC4800
XMC4300
Figure 2 Simplified block diagram of the inverter
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The reference board at a glance
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
1.3 Main features
FP100R12W3T7_B11: EASY3B IGBT7 module for high-current and high-power density [3]
TLI4971-A120T5: XENSIV
TM
current sensor for measuring high currents with minimal power loss [4]
1ED3131MC12H: Gate driver for optimal EMI performance and reduced power losses [5]
IMBF170R1K0M1: Infineon CoolSiC
TM
MOSFET 1700 V enables direct drive by most flyback controllers [6]
XMC4800-F144F2048 and XMC4300-F100K256 AA: XMC microcontrollers for inverter control and
communication [7]
1.4 Board parameters and technical data
The key parameters of the REF-22K-GPD-INV-EASY3B are shown in Table 2.
Table 2 Parameters of REF-22K-GPD-INV-EASY3B
Parameter
Symbol
Conditions
Value
Unit
Input line voltage
Vin
Three-phase AC ± 10%
380 … 480
V
Input frequency
fin
± 3 Hz
50 … 60
Hz
Output voltage
V
out
three-phase AC
0 V … 0.95 x input voltage
V
Output frequency
f
out
0 … 550
Hz
Switching frequency of
motor output
fsw
Factory setting 4 kHz
4
kHz
Rated power
P
rated
22
kW
Rated current
I
rated
45
A
Low overload - base
load power
PLO
T
amb
<= 35°C
22
kW
Low overload - base
load current
ILO 45
A
High overload - base
load power
PHO 18.5
kW
High overload - base
load current
IHO 38
A
Power losses
P
loss
< 700
W
Weight
m
inv
< 10
kg
Ambient temperature
T
amb
Relative humidity RH; 30% <
RH< 80%
10 to 35
°C
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The reference board at a glance
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
1.4.1 Overload profile normal duty
The normal duty (ND) load cycle assumes a uniform base load with low requirements during short acceleration
times at high torque; see Figure 3. Typical applications when designing according to normal duty include:
- Pumps, fans and compressors
- Wet or dry blasting technology
- Mills, mixers, kneaders, crushers, agitators
- Basic spindles
- Rotary kilns
- Extruders
Typical converter load cycle:
110% I
LO
= 50 A
60
300
time in s
100% of I
LO
= 45 A
current
in A
Figure 3 Overload profile normal duty
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The reference board at a glance
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
1.4.2 Heavy duty overload profile
The heavy duty (HD) load cycle permits dynamic accelerating phases at a reduced base load; see Figure 4.
Typical applications when designing according to heavy duty include:
- Horizontal and vertical conveyor technology (conveyor belts, roller conveyors, chain conveyors)
- Centrifuges
- Escalators/moving stairways
- Lifters
- Elevators
- Gantry cranes
- Storage and retrieval machines
Typical converter load cycle:
150% of I
HO
= 57 A
60
300
100% of I
HO
= 38 A
time in s
Figure 4 Overload profile heavy duty
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System and functional description
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
2 System and functional description
2.1 Commissioning
The REF-22K-GPD-INV-EASY3B must be connected to a TN-S line system as shown in Figure 5. The connections
to the inverter can be made only after the converter is unpacked and all packaging material has been removed.
Ref_22k_GPD-INV_Easy3B
Transformer
or generator
L1
L2
L3
N
PE
Figure 5 Connection of the inverter to TN-S line system
A TN-S system transfers the PE protective conductor to the installed plant or system using a cable. Generally, in
a TN-S system, the neutral point is grounded. A TN system can transfer the neutral conductor N and the PE
protective conductor either separately or combined. Also the connection to a TT system is permissible, but the
connection to an IT is not permissible. The reason here is the missing or high-impedance earth connection.
The connection of the inverter is shown in Figure 6. The cross-section of the wires for the line connection, the
brake chopper and the motor cable are in the range of 1.5 to 10 mm². Ensure that the inverter is in a no-voltage
condition and the DC-link is discharged.
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System and functional description
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
To connect the line feeder cables (L1, L2, L3 and PE), see Figure 6. To ensure correct fusing, it is recommended
to make a selection according to IEC is 3NA3824 (80A). Also, connect the motor feeder cables (PE, U, V and W) to
the inverter. The connection of a brake resistor is optional.
L1
L2
L3
PE
PE
U
V
W
R
brake
Figure 6 Connecting of the inverter
Also connect a USB cable to the inverter allowing for communication with the drive. The USB port is located at
the front of the inverter; see Figure 7.
Figure 7 USB port of the inverter
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System and functional description
User guide for REF-22K-GPD-INV-EASY3B
A reference design for a general purpose drive
Before you start the inverter, you need to install the XMC driver and launch the GUI. The software can be
downloaded via Infineon.com. Please register your inverter to get access to the software.
For installation, it is required to have admin rights on your computer. The software was tested with a laptop
(HP EliteBook 840 G5) and Windows 10 Enterprise (Build: 10.0.17134). You have to first install the USB driver, so
extract the file XMC_WinUSBDriver.zip.
To start with the installation, connect your computer with a USB cable to the inverter, and apply an appropriate
voltage to the line feeder cable. The inverter will start operation in idle mode. Now you can install the USB
driver: Go to “Control Panel\All Control Panel Items” then to “Device Manager.” Select the new USB device
“Infineon WinUSB Device;” see Figure 8 part 1, and double click it.
Figure 8 USB device installation
The window, as shown in Figure 8 part 2, will then appear. Click on the “Driver” tab, then “Update Driver” as
shown in Figure 8 part 3. Now select the extracted folder “XMC_WinUSBDriver” as shown in Figure 8 part 4. Click
on “OK” and close all windows you opened previously. The USB driver is now installed.