INTELLIGENT POWER MODULE Model No : PEC16DSMO1

INTELLIGENT POWER MODULE
(Model No : PEC16DSMO1)
User Manual
Version 2.0
Technical Clarification /Suggestion :
N / F
Technical Support Division,
Vi Microsystems Pvt. Ltd.,
Plot No :75,Electronics Estate,
Perungudi,Chennai - 600 096,INDIA.
Ph: 91- 44-4204 8142, 91-44-2496 3142
Mail : service@vimicrosystems.com,
Web : www.vimicrosystems.com

CONTENTS
1. Intelligent Power Module
1.1 Introduction 1
1.2 About Our Trainer
Front panel view 2
Front panel Description 3
Connector Details 4
1.3 Specifications 5
1.4 Applications 9
2. Hardware Description 10
2.1 Intelligent Power Module 11
2.2 IPM Protection 11
i. Self protection 11
ii. Under- voltage lock-out protection 12
iii. Over - temperature protection 13
iv. Over - current protection 14
v. Short circuit protection 15
2.3 Interface Circuit for Seven - pack IPM 16
2.4 Handling Precaution for IPM 17
2.5 High Voltage Input DC - DC Converter 18
2.6 IPM Power Supply 19
3. Voltage and Current Sensor 20
3.1 Hall effect 21
3.2 Hall effect current transducer 22
3.3 Hall Effect Closed Loop Current Transducers 22
3.4 Unipolar Power Supply 26
3.5 Hall Effect Closed Loop Voltage Transducers 27
4. Signal Conditioner 28
5. Protection Circuit 31
6. Opto Coupler 32

7. Three Phase Diode Bridge Rectifier 33
8. Speed Sensor
8.1 Optical Encoder 34
8.2 Quadrature Encoder Pulse
i. Introduction 35
ii. QEP Inputs 36
iii. Two Channel Optical Encoder 37
8.3 Connector Details 39
9. Frequency to Voltage Converter 40
10. General Instruction 41

PREFACE
PEC16DSM01 is a reference manual for INTELLIGENT POWER MODULE. This manual
briefly explains each and every section present in the module. We hope that these modules will
help in setting up a good power electronics laboratory in a simple manner. It is laboratory type
module, so power electronics staff can teach the students easily with guidance of technical
reference manual and our installation engineer.
Power electronics modules are installed by our Qualified engineer, hence customer can
clarify the technical details, service tips thoroughly from our installation engineer about
module. This is very helpful to solve the occurrence of minor fault (cause due to
mishandling / poor maintenance) without our service engineer.
Earnest effort has been made to present details in a simple fashion. We do welcome suggestions
regarding the improvement of module and this manual.
Write to
Technical Support Division,
Vi Microsystems Pvt. Ltd.,
Plot No. 75, Electronics Estate,
Perungudi, Chennai-600 096.
India
Phone: 91-44-2496 1842, 2496 1852.
E-mail: sales@vimicrosystems.com

IPM BASED POWER MODULE PEC16DSMO1
Vi Microsystems Pvt. Ltd., [ 1 ]
1. INTELLIGENT POWER MODULE
1.1 INTRODUCTION
IPM basedpowermoduleworkasDC- DC Converter (Chopper)or DC-AC Converter (Inverter).
It works using a IGBT based IPM and works on basis of software from DSP Processor. The
power module can be used for studying the operation of chopper, three phase inverter, single
phase inverter and speed control of three phase induction motor, single phase induction motor.
Intelligent Power Modules (IPMs) are advanced hybrid power devices that combine high speed,
low loss IGBTs with optimized gate drive and protection circuitry. Highly effective over-current
and short-circuit protection is realized through the use of advanced current sense IGBT chips that
allow continuous monitoring of power device current. System reliability is further enhanced by
the IPM's integrated over temperature and under voltage lock out protection.
IPM has been optimized for minimum switching losses in order to meet industry demands for
acoustically noiseless inverters with carrier frequencies up to 20KHz. The built in gate drive and
protection has been carefully designed to minimize the components required for the user supplied
interface circuit.
This manual provides details of the hardware description of IPM based power module, it also
provides the step-by step procedure of the various experiments.
1.2 ABOUT OUR TRAINER
The following figure shows the front panel of "IPM BASED POWER MODULE
PEC16DSMOl".
Figure - 1

FRONT PANEL VIEW
Figure - 1.1

FRONT PANEL DESCRIPTION
R,Y,B = Applied to 3 phase AC input supply.
U,V,W = Three phase R, Y, B output terminals.
BR1 & BR2 = Breaking Rheostat (470S - 2A).
+HV = Rectifier with filter DC output voltage (DC link voltage).
Voltmeter = Read the DC link voltage.
V/2 = Voltage across V/2 is half of the DC link voltage.
Feed back signals (Isolated current/voltage/speed sensor output)
1 2 3 1 2I , I , I = 3 phase R,Y,B current transducer output currents are I , I ,
3I respectively and measure this current across the
terminals U, V and W.
DCV = DC link voltage (voltage transducer output).
DCI = DC link current ( current transducer output).
N(Speed) = Analog voltage ( 0 - 5V).
F = Fault output signal comes from IPM, when over
temperature/current occurs.
MCB = Power ON/OFF the 3 phase AC supply.
Power = Power ON/OFF the control circuits.
IGBT - PWM Inputs (from controller)
PWM1,.... PWM6 = PWM pulses are coming from controller.
PWM output
High - 5V = IGBT ON.
Low - 0V = IGBT OFF.
CAP1,.......CAP6 = Capture input to processor.
Protection Circuit
RST = Reset the protection circuit, then 'SD' LED will be off.
SD = Shut down LED will glow, when over voltage/current
occurs in power circuit.

CONNECTOR DETAILS
Fig - 1.2
Pin Details ( The following specific pin numbers are used to your own design applications. Don’t
change the specific pin numbers).
34 pin FRC Connector 26 Pin FRC Connector
1 PWM1 5 N - SPEED
3 PWM2 7 I1(IR)
5 PWM3 9 I2 (IY)
7 PWM4 11 AFOUT
9 PWM5 21 IDC
11 PWM6 23 I3 (IB)
2,4,13,15,17,19 No Connection 25 VDC
21 BREAK 1,2,3,4,13,15,1
7,19
No Connection
23 SD
25 CAP1/QEP1/IOPC4 12,14,16,18,20,
22,24,26
GND
27 CAP2/QEP2/IOPC5
29 CAP3/IOPC6 Note : Pin No 5 - N (Speed)
Analog voltage (0-5V) is apply to
directly. Don’t apply to speed pulse
signal.
31 CAP4/IOPC7
33 PDPINT
6,8,10,12,14,16,18,20,
22,24,26,28,30,32,34
GND
Pin No - 25, 27, 29, 31 (Speed feed back pulse
signal - is directly apply to required pin numbers
1 3 5 7 9 11 13 15 17
2 6 12 16 20 24 28 32 34302622181484 10
292725232119 31 33
34 Pin FRC 26 Pin FRC
19 21 23 251715131197531
104 8 14 18 22 262420161262

1.3 SPECIFICATIONS
Input
* Three - phase AC supply (415V±10%)
* Single - phase AC supply (230V±10%)
Output
* DC Link voltage - 750V DC.
* Max. Current - 8A.
* Three- phase variable voltage & variable frequency.
* Fixed and variable DC voltage
* Single - phase variable voltage & variable frequency.
Test point Voltage ratings
1. IDC
Fig - 1.3
2. I1, I2, I3
No Load ( Normal) (V) = 1.6V
Apply Load 1A (V) = 1.6 + 0.17 SinTt
t
V
Apply Load
t
( No Load )
0
Upto 1A
Normal
.33V

Fig - 1.4
0 t
.17V
.34V
.51V
.68V
0
0
0
t
t
t
t
t
t
1.6V
Load = 4A
Load = 3A
Load = 2A
No Load
Load = 1A
1.6V
1.6V
1.6V
1.6V
0
V
t
t

The figure -1.4 the output frequency is depends upon PWM techniques.
i. Sinusoidal PWM
ii. Space vector PWM
TYPE OF PWM FREQUENCY RANGE
Minimum Maximum
Sinusoidal 1 Hz 50Hz
Space Vector 1 Hz 50Hz
Note:
IGBT
Switching Frequency - 5KHz to 10KHz.
Dead time - 5:s(Minimum).
VDC - Maximum value of DC link voltage = 750V at that time output voltage
of test point terminal VDC = 3.3V.
Fault - Fault occurred in a system.
The Maximum output voltage of fault terminal = 3.3V.
Speed - Max voltage of speed terminal is 2.6V at Motor rated speed 1500rpm.
Break - Break pulse output Amplitude = 5V.
PWM1 to PWM6- The Max Amplitude of PW1 to PWM6 (test points) = 5V with respect to
GND.

DEVICE SPECIFICATIONS
Bridge Rectifier - 3N diode bridge Rectifier (60A,1200V)
IGBT Intelligent power module ( 25A, 1200V)
* Switching frequency = 20KHz (Max), 10KHz Nominal.
* Braking of IGBT = 10A, 1200V (Max). 6A Nominal.
FO* Fault output current (I ) = 20mA (Max)
FO* Fault output voltage (V ) = 20V (Max)
Voltage Transducer (LV25-P)
PN* Primary nominal r.m.s. current (I ) = 10mA
PN* Primary nominal r.m.s voltage (V ) = 10 to 500V
SN* Secondary nominal r.m.s current (I ) = 25mA
Current Transducer (LTS 25-NP)
PN* Primary nominal r.m.s current (I ) = 8-12-25A
b* R.M.S rated voltage( V ) = 525V
out p* Analog output voltage (V ) = 2.5V (I = 0)
IPM Power Supply
* Output = Four +15V supply Max
power=3W
Rms* Primary to Secondary isolation = 2500 V , one minute
Rms,* Secondary to Secondary isolation voltage = 1500 V one minute
High Voltage Input DC-DC Converter
* input voltage (Vin) = 113V to 400V DC
* output voltage (Vout) = 18 to 22 V DC
* Load Current = 220mA
For more details of device specifications refer the data sheets.

1.4 APPLICATIONS
The IPM Based power module can be used for the following study experiments.
i. To study the output voltage/current wave forms of
1. Three phase inverter with star connected R and RL Load .
2. Three phase inverter with delta connected R and RL Load
3. Four Quadrant chopper unipolar switching with R and RL-Load.
4. Single Quadrant chopper with R and RL-Load.
ii. To study the motor speed control (Open Loop)
5. Separately excited DC shunt motor by using four quadrant chopper with unipolar
6. Three phase induction motor by using different PWM techniques (sinusoidal, V/F
and space vector Modulation).
7. Single phase induction motor by using sinusoidal pulse width modulation
technique only.
iii. To study the motor speed control (Closed Loop)
8. Separately excited DC shunt motor by using four quadrant chopper with unipolar
9. Three phase induction motor by using different PWM techniques (sinusoidal, V/F
and space vector Modulation).
10. Single phase induction motor by using sinusoidal pulse width modulation
technique only.
Note
The following motor controls are possible in PEC16DSMO1 module
* Brush less DC motor (BLDC)
* Permanent Magnet Synchronous Motor (PMSM)

2. HARDWARE DESCRIPTION
Figure - 2 Block Diagram for IPM based power module
The block diagram of IPM Based Power Module (PEC16DSMOl) is shown in Figure (2). It
consists of a
1. Intelligent Power Module
2. Voltage and Current Sensor
3. Signal Conditioner
4. Protection Circuit
5. Opto Coupler
6. 3 N diode bridge Rectifier
7. Speed Sensor
8. Frequency to Voltage converter
+15V +15V +15V 0V
+
-
ISOLATED
POWER SUPPLY
HIGH VOLTAGE
INPUT DC-DC
CONVERTER
DSP / MICRO - CONTROLLER
U
V
W
VDC
VOLTAGE &
CURRENT
CONDITIONAR
SIGNAL
BRIDGE
RECTIFIER
3-Ø DIODE
IPM - PM25RSB120
SENSOR
PROTECTION CIRCUIT
SPEED
SENSOR
VDC
IDC
BYR
SUPPLY
3 Ø AC
MCB
P
N
B
INPUT
SIGNAL
FAULT
OUTPUT
I1 2I 3I 4I
3 Ø
MOTOR
HGND v+
OPTO
COUPLER (3)
OPTO
COUPLER (1)
OPTO
COUPLER (2)
PC
AFOUT
IR IY IB
PDPINT
PWM
BREAK
CONVERTER
F/V
IPM BASED
POWER MODULE
[ PEC16DSMO1 ]

2.1 INTELLIGENT POWER MODULE
Mitsubishi Intelligent power Modules utilize many of the same field proven module packaging
technologies used in Mitsubishi IGBT modules. Cost effective implementation of the built in gate
drive and protection circuits over a wide range of current ratings was achieved using two
different packaging techniques. Low power devices use a multilayer epoxy isolation system while
medium and high power devices use ceramic isolation.
2.2 IPM PROTECTION
The following protection schemes available for Intelligent power Module.
i. Self Protection
ii. Under-Voltage Lock-Out Protection
iii. Over-Temperature Protection
iv. Over-Current Protection
v. Short Circuit Protection
i. SELF PROTECTION
IPM (Intelligent power Modules) have sophisticated built-in protection circuits that prevent the
power devices from being damaged should the system multifunction or be over stressed IPM
internally builded the fault detection and shut down schemes that allow maximum utilization of
power device capability without compromising reliability Control supply under -voltage, over-
temperature, over-current, and short-circuit protection are all provided by the IPM's internal
gate control circuits. A fault output signal is provided to alert the system controller if any of the
protection circuits are activated. Figure 2.1.1 is a block diagram showing the IPMs internally
integrated functions. This diagram also shows the isolated interface circuits and control power
supply that must be provided by the user.
The internal gate control circuit requires only a simple +15V DC supply. Specially designed gate drive
circuits eliminate the need for a negative supply to off bias the IGBT. The IPM control input is designed
to interface with Optocoupled transistors with a minimum of external components.
Figure - 2.1.1 IPM Functional Diagram

ii. UNDER-VOLTAGE LOCK-OUT PROTECTION
Figure - 2.1.2 Operation Of Under - Voltage Lockout
TheIntelligent PowerModule's internal control circuits operate from anisolated15VDC supply.
If for any reason, the voltage of this supply drops below the specified under-voltage trip level
t(Uv , the power devices will be turned off and a fault signal will be generated. small glitches less
duvthan the specified t in length will not affect the operation of the control circuitry and will be
ignored by the under voltage protection circuit .In order for normal operation to resume, the
supply voltage must exceed the under-voltage reset level (Uvr).
Operation of the under voltage protection circuit will also occur during power up and power
down of the control supply. This operation is normal and the system controller's program should
fotake the fault output delay (t ) into account. Figure - 2.1.2 is a timing diagram showing the
operation of the under-voltage lock-out protection circuit. In this diagram an active low input
signal is applied to the input pin of the IPM by the system controller. The effects of control
supply power up, power down and failure on the power device gate drive and fault output are
shown.
Caution
1. Application of the main bus voltage at a rate greater than 20V/µs before the control
power supply is on and stabilized may cause destruction of the power devices.
2. Voltage ripple on the control power supply with dv/dt in excess of 5V/µs may cause a
false trip of the UV lock-out.

iii. OVER-TEMPERATURE PROTECTION
The Intelligent power Module has a temperature sensor mounted on the isolating base plate near
the IGBT chips. If the temperature of the base plate exceeds the over temperature trip level (OT)
the IPMs internal control circuit will protect the power devices by disabling the gate drive and
ignoring the control input signal until the over temperature condition has subsided.
In six and seven pack modules all three low side devices will be turned off and a low side fault
signal will be generated. High side switches are unaffected and can still be turned on and off by
the system controller. Similarly, in dual type modules only low side device is disabled. The fault
output will remain as long as the over temperature condition exists. When the temperature falls
below the over temperature reset level (OTr ), and the control input is high (off state) the power
device will be enabled and normal operation will resume at the next low(on) input signal.
Figure2.1.3 is a timing diagram showing the operation of the over temperature protection circuit.
The over temperature function provides effective protection against overloads and cooling
system failures in most applications. However, it does not guarantee that the maximum junction
temperature rating of the IGBT chip will never be exceeded. In cases of abnormally high losses
such as failure of the system controller to properly regulate current or excessively high
switching frequency it is possible for IGBT chip to exceed Tf(max) before the base plate reaches
the OT trip level.
Figure - 2.1.3 Operation of Over - Temperature
Caution
Tripping of the over-Temperature protection is an indication of stressful operation. Repetitive
tripping should be avoided.

iv. OVER-CURRENT PROTECTION
The IPM uses current sensing IGBT chips to continuously monitor power device current. If the
current though the intelligent power Module exceeds the specified over current trip level (OC)
for a period longer than toff (OC). The IPMs internal control circuit will protect the power device
by disabling the gate drive and generating a fault output signal. The timing of the over- current
protection is shown in Figure2.1.4. The toff (OC) delay is implemented in order to avoid tripping
of the OC protection on short pulses of current above the OC level that are not dangerous for the
power device.
When an over-current is detected a controlled shut down is initialized and a fault output is
generated. The controlled shut down lowers the turn-off di/dt which helps to control transient
voltages that can occur during shut down from high fault currents. Most intelligent modules use
the two step shutdown depicted in Figure 2.1.4 the two step shutdown, the gate voltage is
reduced to an intermediate voltage causing the current through the device to drop slowly to a low
level. Then, about 5µs later , the gate voltage is reduced to zero completing the shut down. Some
of the large six and seven pack IPMs use an active ramp of gate voltage to achieve the desired
reduction in turn off di/dt under high fault currents.
Figure - 2.1.4 Operation of Over-Current and Short-Circuit protection

V. SHORT CIRCUIT PROTECTION
If a load short circuit occurs or the system controller malfunctions causing a shoot through, the
IPMs built in short circuit protection will prevent the IGBTs from being damaged. When the
current, through the IGBT exceeds the short circuit trip level (SC), an immediate controlled
shutdown is initiated and a fault output is generated. The same controlled shutdown, techniques
used in the over current protection are used in the over current protection are used to help
control transient voltages during short circuit shut down.
The short circuit protection provided by the IPM uses actual current measurement to detect
dangerous conditions. This type of protection is faster and more reliable than conventional out-
of-saturation protection schemes. Figure 2.1.4 is a timing diagram showing the operation of the
short circuit protection.
To reduce the response time between SC detection and SC shutdown, a real time current control
circuit (RTC) has been adopted. The RTC bypasses all but the final stage of the IGBT driver in
SC operation thereby reducing the response time to less than 100 ns.
Caution
1. Tripping of the over current and short circuit protection indicates stressful operation of
the IGBT. Repetitive tripping must be avoided.
2. Highsurge voltages can occur during emergency shutdown.Lowinductancebusworkand
snubbers are recommended.

2.3 INTERFACE CIRCUIT FOR SEVEN-PACK IPM
The following Figure 2.1.5 show the interface circuit for seven-pack IPM
Figure - 2.1.5 Interface Circuit for Seven - Pack IPM

2.4. HANDLING PRECAUTIONS FOR IPM
i. Electrical Considerations
* Apply proper control voltages and input signals before static testing.
* Carefully check wiring of control voltage sources and input signals. Miswiring
may destroy the integrated gate control circuit.
* When measuring leakage current always ramp the curve tracer voltage up from
zero. Ramp voltage back down before disconnecting the device. Never apply a
voltage greater than the VCES rating of the device.
* When measuring saturation voltage low inductance text fixtures must be used.
Inductive surge voltages can exceed device ratings.
ii. Mechanical Considerations
* Avoid mechanical shock. The module uses ceramic isolation that can be cracked
if the module is dropped.
* Do not bend the power terminals. Litting or twisting the power terminals may
cause stress cracks in the copper.
* Do not over torque terminal or mounting screws. Maximum torque specifications
are provided device data sheets.
* Avoid uneven mounting stress. A heatsink with a flatsink with a flatness of
0.001"/1" or better is recommended. Avoid one sided tightening stress. Uneven
mounting can cause the modules ceramic isolation to crack.
iii. Thermal consideration
* Do not put the module on a hot plate. Externally heating the module's base plate
at a rate greater than 15o
C/min. will cause thermal stress that may damage the
module.
* When soldering to the signal pins and fast on terminals avoid execesive heat. The
soldering time and Temperature should not exceed 230o
C for 5 seconds.
* Maximize base plate to heatsink contact area for good heat transfer. Use a
thermal interface compound such as white silicon grease. The heatsink should
have a surface finish of 64 microinches or less.

2.5. HIGH VOLTAGE INPUT DC-DC CONVERTER
M57120L is a non-isolated DC-to-DC converter with a built in transformer wide range
of input voltage (DC 113V-400V) enables direct connection to rectified 120V and 240V
AC. This device is best suited for use as a pre regulator for standard DC-to-DC
converters. The schematic diagram for High voltage input DC-DC Converter as shown
in Fig 2.1.6.
Fig - 2.1.6 High Voltage input DC-DC Converter
Application
1. Power source for standard DC-to-DC Converter
2. Pre-regulator.

2.6. IPM POWER SUPPLY
M57140- 01 is an isolated DC-to-DC converter designed to drive IPMs (Intelligent Power
Modules) with an input of DC 20V, The module supplies four 15V outputs. Isolation is provided
from primary to Secondary and also between the secondaries. Interwinding isolation is designed
for driving the IPM. IPM power supply schematic diagram is as shown in Fig 2.1.7
Fig - 2.1.7 IPM Power Supply
IPM power supply output is connected to the power pin of IPM PM25RSB120. The M57410-01
is used under excessive Load condition, output side rectifying diodes will be destroyed. Care
should be exercised so as not to operate the device above the rated maximum Load current (To
see the figure 2.1.7).
Coating Materials should not be applied on this device because the application of coating
Materials for water proofing could cause a stress and destroy a device.
Applications
1. General purpose inverter and AC servo
2. Power source for MOSFET Driving circuits.

3. VOLTAGE AND CURRENT SENSOR
Intelligent power module output voltage and current is not directly feed to control (Protection)
circuits. Intelligent power module output voltage is very high but control circuit operated in
minimum voltage, So necessary for IPM output high voltage is convert into very low Voltage and
current transducer sense from high voltage and output of transducer is low voltage (max 5V).
The block diagram for voltage and current transducer output is as shown in fig-2.2.
Figure - 2.2. Voltage and Current Transducer
The sensor used for sensing current and voltage are works on the principle of hall effect, Hence
these sensors are called hall effect transducer. Hall effect transducer output voltage and currents
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 for a typical value of 1 :
1000, a primary current of 1A results in a secondary current of 1 mA. Voltage and current
transducer principles of both are same, but one difference in primary winding of voltage
transducer. The resistance connected in series with the primary winding of voltage transducer.
This resistance can be external or integrated into the transducer construction.
A Hall effect current tranducers senses the current IDC, I1(U), I2(V) I3(W) and one hall effect
voltage transducer senses the DC link voltage (VDC).

3.1. HALL EFFECT
Both the open loop and the closed loop transducers use the Hall effect, which was discovered in
1879 by the American physicist Edwin Herbert Hall, at the John Hopkins University in Baltimore.
The Hall effect is caused by the Lorentz force, which acts on the mobile electrical charge carriers
in the conductor, when they are exposed to a magnetic field that is perpendicular to the current
direction.
A thin sheet of semiconductor material is traversed length-wise by a control current IC (Fig.
2.2.1). The magnetic flux B generates a Lorentz force FL perpendicular to the direction of the
mobile charge carriers composing the current. This causes a change of the number of charge
carriers at both edges of the sheet, thus creating a potential difference referred to as Hall voltage
VH.
Figure - 2.2.1 Representation of the Electrical Parameter of the Hall Effect
For the arrangement, described above, with a magnetic field perpendicular to the current, we
obtain:
VH = (K/d) × IC × B
Where K is the Hall constant for the material used, and d the thickness of the thin sheet. Such an
arrangement is referred to as Hall generator. The Hall effect generators show a certain
dependence of the Hall sensitivity and the offset voltage VOT on temperature, which can, however,
be greatly compensated by the electronic circuit of the current transducer.

3.2. HALL EFFECT CURRENT TRANSDUCER
The LTS 25-NP, a closed-loop current transducer capable to measure DC, AC and impulse
currents with a galvanic isolation. The transducer presents a multi-range configuration designed
for nominal currents of 8A, 12A & 25 A rms. A multitude of connection options are integrated
allowing users to make direct or differential current measurement. As a further advantage the LTS
25-NP is featuring a measuring of more than 3 times IN, thus peak currents up to respectively
25.6A, 38.4A & 80 A can be measured. By integrating the whole electronics in a specific ASIC,
the LEM engineers succeeded in combining a particular high performance with an extremely small
size.
Due to its innovative technology, the LTS 25-NP presents performance that wasn't possible to
achieve with the concept of traditional hall effect closed loop transducers, up to now. In addition
to its miniature size (9.3x22.2x24 mm), the LTS 25-NP has an intrinsic accuracy of +/- 0.2%, an
excellent linearity of less than 0.025% and a bandwidth from DC to 200 kHz. It has to be
underlined that LTS 25-NP has very low temperature drift of only 50 ppm/K typical.
Also new with this concept, the LTS 25-NP is supplied with a unipolar power supply of +5V,
while still capable to measure both positive and negative currents. Therefore a whole supply
branch is no longer requested. In addition, a measuring resistor of 0.5% accuracy has been
incorporated which is characterised by a very low temperature drift, this provides directly a
voltage output. This output is set at 2.5V at zero primary current with a variation span of 0.625
V at nominal current. Thus the transducer can directly be connected to the 5V input of
microcontrollers, A/D converters and instrumentation cards.
3.3 HALL EFFECT CLOSED LOOP CURRENT TRANSDUCERS
The closed loop transducers (also called compensation or zero flux transducers) have an
integrated compensation circuit by which the performance of the current transducers using the
Hall effect can be markedly improved.
i. Construction and principle of operation
Whereas the open loop current transducers give a VOUT output voltage proportional to the
amplified VH Hall voltage, the closed loop transducers supply a secondary current IS proportional
to VH which acts as counter-reaction signal in order to compensate the induction created by the
primary current BP by an opposed secondary induction BS.
The secondary current IS , reduced by the turns ratio, is much lower than IP , because a winding
with NS turns is used to generate the same magnetic flux (ampere-turns). One thus selects:
NP × IP = NS × IS

Figure - 2.2.2 Operating Principle of the Closed Loop Transducer
The BS induction is thus equivalent to BP and their respective ampere-turns counter balance each
other (compensate). The system thus operates at zero magnetic flux (fig. 2.2.2).
Let us take as an example the measurement of a DC current of 100 A.
The number of turns NP = 1, because the conductor leads directly into the magnetic circuit,
thereby constituting a single turn.
The secondary winding has NS = 1000 turns.
The turns ratio is thus 1:1000.
As soon as IP takes a positive value BP induction appears in the air gap of the magnetic core,
producing a VH voltage in the Hall element. This voltage is transformed into a current by way of
a current generator the amplifier stage of which supplies the IS current flowing through the
secondary winding. The BS induction is thus created which compensates the BP induction.
The resulting secondary current is thus:
IS is thus the exact image of IP. This is the measurement current intended for the user.

LTS Series: New generation of transducers
The LTS series offers the first closed-loop transducer based on an ASIC (Application Specific
Integrated Circuit). All active electronic components including the Hall sensor are combined in
the ASIC (Fig. 2.2.3). This integration makes it a lot easier to compensate for the component
tolerances and the temperature shift. Moreover, it improves the immunity to EMI, and the
adaptation of the components is optimized. In conjunction with the new technology for the
construction of the magnetic circuit, it has been possible to greatly reduce the housing dimensions.
Figure - 2.2.3 Functional Diagram of the LTS Series
The operating principle remains that of a traditional closed-loop current transducer; the
particularity of the series LTS transducers, however, is an output voltage which is compatible
with the input of an A/D converter of a DSP or microprocessor. This output voltage is generated
across the measuring resistor (R IM ) which is integrated in the transducer. For a given primary
current, the value of the output voltage can be calculated as follows:

Current ranges
The range of the closed loop LEM transducers permits measurement of IPN nominal currents from
a few amperes to several tens of kA, with an accuracy of about 1 %.
With the devices produced by our LEM DynAmp subsidiary, which use the same technology, it
is possible to measure very high currents up to 500 000 A.
This type of transducer can in fact measure a higher current value then the one limited by the
parameters indicated above which define the normal measuring range. The high transient currents,
which however must (for thermal reasons) be of short duration, can indeed be measured. The
transducer operates in this case like a current transformer. Considerations, such as a good
magnetic primary/secondary coupling, must of course be taken into account when mounting the
transducer, in order to obtain satisfactory results.
With the series LTS transducers, the primary-current/output voltage ratio is determined by the
resistor RIM . The reference point without any primary current is 2.5 V, which is exactly half the
supply voltage (0 to +5V). The output voltage as a function of the primary current can be
represented as shown in figure-2.2.4.
Figure - 2.2.4 Output Curve of the LTS Series

iv. Frequency Response
The measurements carried out on the closed loop transducers show an excellent frequency
response. This band-width is due to two phenomena. For the DC current and the low frequencies,
the electronics with the Hall element is determining. In the high frequency regions the transducer
operates as a current transformer (Fig. 2.2.5). The minimum high frequency limit for most of
current transducers is equal to 100 kHz. Some models even reach a bandwidth of 150 to 200 kHz.
Figure - 2.2.5 If the frequency is increased, the closed loop transducer then
operates as a current transformer
Thanks to the combined optimization of the bandwidth of the electronic circuit and the frequency
bandwidth of the current transformer it is possible to cover these two frequency regions,
providing high accuracy over the product’s whole frequency bandwidth. LEM has thus created
a special product range, the principle of which is patented, the LB transducer series. Their
frequency bandwidth has been linearized and extended to over 300 kHz.
3.4. UNIPOLAR POWER SUPPLY
Most of the LEM transducers can also be supplied by an unipolar voltage for measurement of
unidirectional currents. In this case the following must be taken into consideration:
1. The supply voltage is the sum of the positive and negative voltages indicated in the data sheet.
2. The load resistance shall be calculated separately, in order not to exceed the acceptable
dissipated power of the amplifier’s final stage. As a first approximation this calculation is
not necessary if one does not exceed half of the nominal primary current. In other cases
please consult us.
3. As the amplifier circuit is designed for a bipolar power supply and is used here as unipolar,
diodes must be inserted into the measuring circuit, as shown in Fig. 2.2.6. This is in order
to compensate the residual voltage across the unused output transistor which could
generate a current comparable to an offset in the measuring circuit.

Furthermore, variants specially adapted for unipolar operation are available as a standard device.
Figure - 2.2.6 Disposition of diode(s) with an unipolar power supply
3.5 HALL EFFECT CLOSED LOOP VOLTAGE TRANSDUCERS
The Hall effect voltage transducers are based on the same principle as their current transducer
counterpart. They are in fact constituted by a current transducer assembly where the main
difference is in the primary circuit which is made with a winding having a high number of turns.
This permits realization of the necessary ampere-turns for the creation of the primary induction,
while having a low primary current, thus permitting a minimal consumption in the circuit to be
measured.
To measure a voltage it is therefore sufficient to shunt from this voltage the equivalent primary
current which will supply the transducer. This is carried out with the help of a resistance
connected in series with the primary winding. The Hall effect voltage transducers are therefore
constituted by a current transducer assembly and a primary resistance named R1. This resistance
can be external or integrated into the transducer construction.

4. SIGNAL CONDITIONER
Figure - 2.3 Signal Conditioner
The basic block diagram for signal conditioner is as shown in figure 2.3. This section is used to
give the reference signals of current and voltage to the protection circuit as well as to the ADC
of the DSP Processor.
DC Link Voltage
DC Link voltage is sensed using a hall effect voltage sensor and the output of that transducer
is given to the non-inverting amplifier. Then the output of that amplifier is given to a inverting
amplifier here the gain of the amplifier can be adjusted using a Trimpot (TR9). Then the output
is compared with reference voltage which is already set, then the output is given to hardware
protection unit as well as to ADC channel of the DSP processor through a 5V voltage regulator.

DC Link Current
DC Link current is feed from a hall effect current transducer, it is given to the non-inverting
amplifier here the offset voltage can be adjusted using the trimpot (TR4). Then the gain can be
adjusted using the trimpot (TR1). The I1 current is given to the active filter section, active filter
output is connected to ADC channel of the DSP Processor. I1 current is compared with reference
value by using comparator section and it is given to the hardware protection unit.
R, Y, B Phase Current
These currents are sensed by using 3 separate hall effect transducer then these currents are given
to non-inverting amplifiers here the offset voltage can be set. Then the output is given to
inverting amplifier here the gain can be set.
Finally the outputs are given to the ADC channel of DSP. IPM Based Power Module
(PEC16DSMO1) is working in speed control of DC motor, chopper circuits, three phase inverter
and single phase inverter. The Phase currents are R, Y, B is equal to I1, I2 and I3 currents.
Offset Voltage
Hall effect transducer output signal is sinusoidal but DSP processor need only positive voltage
and to reject the negative voltage. So DSP Processor will not be control the protection circuit
and any other control circuit. To ignore this problem, input of sinusoidal signal is shifted to the
positive voltage level. Max offset voltage for DSP Processor is 0 to 3.3V.
When the DC offset voltage is set with transducer output signal, the input signal is shifted
positively. The offset voltage and gain value is varied by some specifical applications and
research purpose to adjust the trimpot.
Vary the DC link current, DC link voltage and R(I1), Y(I2), B(I3) phases offset voltage and gain
value by varying the trimpot. The following table is used to adjust the trimpot to the
corresponding offset voltage and gain values of DC link current, DC link voltage and R(I1), Y(I2)
and B(I3) phase current.
OFFSET VOLTAGE GAIN
DC Link voltage Vout - TR9
DC Link Current TR4 TR1
R-Phase (I1) Current TR3 TR2
Y-Phase (I2) current TR5 TR6
B-Phase (I3) Current TR7 TR8

Active Filter
Electric filters are used practically in all circuits which require the separation of signal according
to their frequencies. Applications include noise rejection and signal separation in industrial and
measurement circuits, feedback of phase and amplitude control in servo loops, smoothing of
digitally generated analog (D- A) signals, audio signal shaping and sound enhancement, channel
separation and signal enhancement in communication circuits.
Such filters can be built from passive RLC components, electromechanical devices, crystals or
with resistors, capacitors and op-amps (Active filters). Active filters are applicable over a wide
frequency range, are in expensive and offer high input impedance, low output impedance gain, and
a wide variety of responses.
Electronically controlled active filters allow adaptive and automated filtering. Active filter input
impedance is very high and output impedance is very low.
Hall effect transducer is rippled output current, it is not directly used to processor or controller.
The processor or controller used to only constant value. The ripple current to be changed to
constant output current by using active filters.
The DC link current I1 is connected to the input of active filter. Active filter output is connected
to ADC input of any processor or controller.

5. PROTECTION CIRCUIT
Figure - 2.4 Protection Circuit
The schematic diagram for protection circuit of IPM based power module is as shown in
figure2.4. Protection circuit is used to prevent the over voltage, over current and under voltage.
The current and voltage from signal conditioner's are given to input of master / slave JK Flip
flops. Master / Slave JK flip flop output is connected to transistors Q1 and Q2. Transistor Q1
output C1 terminal is given to input of AND-7 & AND-(1-6) Gates. AND (1-6) Gates another
input is feed from PWM output of DSP. These output of AND Gates depends upon transistor
Q1 output, then AND gates output is given to input of optocoupler (1), then optocoupler (1)
output signal is feed to input of IPM. IPM is generate to the fault output signals, when over
current/ voltage occurs an IPM. This signal is feed to optocoupler (2) and optocoupler (2)
output is ANDed with Q1 output (C1) signal. The AND7 gate output is given to input of
PDPINT (DSP). Normal condition PDPINT - high, PDPINT is disable when over temperature
and over current occurred in power circuit of joint to C1.
Many protection hardware requirement is builded to this protection circuit, when over voltage
or over current occurs in a power circuit, the DSP.CT.IN or DSP.VOLT.IN output is high '1',
input of master/slave Jk Flip flop J = 1, output Q = 1, Q' = 0, then transistor Q1 and Q2 conduct
and shut down LED "SD" will glow (LED Glow to indicate the power circuit affected by the
over voltage / over current) at that same time transistor Q1 output (C1 terminal) is 0V. Then
AND (1-6) & AND 7 gate output is low '0', then automatically cut the PWM signal to IPM and
shutdown the IPM.
Voltage and current sensor, output is feed to ADC of DSP. When, find out the over voltage /
current from the ADC inputs of DSP. Then cut the PWM signal to protection circuit and
shutdown the IPM.
JKFFR
S Q
Q
S
R
Q
Q
DSP
MICROCONTROLLER
P
OPTO COUPLER(1)
IPM
OPTO COUPLER(2)
COUPLER(3)
OPTO
FAULT
OUTPUT
SIGNAL
INPUT
Break
DSP.CT.IN
DSP.VOLT.IN
RESET SWITCH
LED +5V
+5V
C1
PROTECTION CIRCUIT
PDP INT
WM1 WM6P
Break
FROMSIGNALCONDITIONER
MASTER / SLAVE
MASTER / SLAVE
JKFF
or
Q1
Q2
AND-7
AND-6AND-1

Signal conditioner outputs of DSP.VOLT.IN and break signal from DSP, both signals are feed
to Optocoupler (3). This output given to input of IPM module. Both signals are enable, when
over voltage / current occurs to the IPM at that time input of IPM BR signal is enable after that
shutdown the IPM unit.
6. OPTO COUPLER
The function of Opto Coupler is isolate to the control circuit from power circuit. Pulse width
modulation signal (PWM 1 to PWM 6) comes from DSP Processor. This signal is not directly
feed through a power circuit. Suppose Control Circuit (DSP) is connected to power circuit
without isolation circuit, the control circuit may get affected so needed to isolation circuit
interface between power circuit and control circuit. The Opto coupler schematic diagram is as
shown in figure 2.5.
Figure - 2.5 Optocoupler
It consists of a Optocoupler (1), Optocoupler (2), Optocoupler (3). PWM signals are feed from
protection circuit into IPM by using opto coupler (1). IPM fault output signal is connected to
optocoupler (2). Optocoupler (3) is connected from protection circuit and break signal.
OPTO
COUPLER
COUPLER
OPTO
COUPLER
OPTO
COUPLER
OPTO
COUPLER
OPTO
COUPLER
OPTO
VUPI
UPCV
PU
VPC
VPI
VP
V
V
WPC
WPI
WP
V
V
NC
NI
UN
V
V
VN
WN
OPTO
COUPLER
COUPLER
OPTO
OPTO
COUPLER
COUPLER
OPTO
OPTO
COUPLER (3)
FO
WFO
VFO
UFO
BR
FROM PROTECTION CIRCUIT
PWM-1
PWM-3
PWM-5
PWM-2
PWM-4
PWM-6
FROMPROTECTIONCIRCUIT
OPTO COUPLER (2)
C1PDPINT
IPM-PM25RSB120
OPTO COUPLER (1)
AND-7

Whenever optocoupler (2) is received the IPM fault output signal, then shut down all the control
circuits and reset the DSP Processor.
7. THREE PHASE DIODE BRIDGE RECTIFIER
This rectifier provides the rectified DC voltage to the intelligent power module. 3 Phase Diode
Bridge Rectifier circuit diagram is as shown in figure 2.6.
Figure - 2.6 Three Phase Diode Bridge Rectifier
Each Three phase line connects between a pair of diodes. One to route power to the positive (+)
side of the load and the other to route power to the negative (-) side of the load. Polyphase
systems with more than three phase are easily accommodated into a bridge rectifier scheme.
3M AC supply is connected to input of 3M bridge rectifier module. 3M bridge rectifier convert
the AC voltage into DC voltage with AC ripples. Capacitor is connected across the bridge
rectifier. Capacitor is used to neglect the AC ripples. 3M diode bridge rectifier module output
is connected to input of intelligent power module.

8. SPEED SENSOR
Motor speed is sensed from the following methods.
1. Optical Encoder
2. Quadrature Encoder Pulse
3. Resolver
8.1 OPTICAL Encoder
A circular windows around the circular disk mounted on the motor shaft such that it rotates
with the shaft. A LED is mounted on the one side of the disk and a phototransistor is
mounted on the other side of the disk, opposite to the LED, the following figure-2.7.1 shows
the speed sensor
Figure-2.7.1 Optical Encoder Speed Sensor
During rotation when circular window come across the LED, the light passes to the
phototransistor. As a result, phototransistor conducts and produces low output at its
collector. Each time when light passes through window to the phototransistor, it conducts
and output goes low, otherwise phototransistor is off and output is high
Figure-2.7.2 Schematic view of Optical Speed Sensor

As disk rotates the train of pulses are generated. The number of pulses in one rotation equals
the number of circular windows on the disk. Therefore by counting number of pulses we can
decide the position of the shaft as well as number of rotations performed by the shaft. By
counting the number of rotations in specific time we can also calculate the speed of rotation.
Counting the number of pulses in specific time, these pulses convert frequency to voltage by
using frequency to voltage converter.
8.2 QUADRATURE ENCODER PULSE
i. Introduction
The enhanced quadrature encoder pulse (eQEP) module is used for direct interface with a
linear or rotary incremental encoder to get position, direction, and speed information from a
rotating machine for use in a high-performance motion and position-control system.
A single track of slots patterns the periphery of an incremental encoder disk, as shown in
Figure 2.7.3. These slots create an alternating pattern of dark and light lines. The disk count
is defined as the number of dark/light line pairs that occur per revolution (lines per
revolution). As a rule, a second track is added to generate a signal that occurs once per
revolution (index signal: QEPI), which can be used to indicate an absolute position. Encoder
manufacturers identify the index pulse using different terms such as index, marker, home
position, and zero reference
Figure-2.7.3 Optical Encoder Disk
To derive direction information, the lines on the disk are read out by two different photo-
elements that “look” at the disk pattern with a mechanical shift of 1/4 the pitch of a line pair
between them. This shift is realized with a reticle or mask that restricts the view of the photo-
element to the desired part of the disk lines. As the disk rotates, the two photo-elements
generate signals that are shifted 90?out of phase from each other. These are commonly called
the quadrature QEPA and QEPB signals. The clockwise direction for most encoders is
defined as the QEPA channel going positive before the QEPB channel and vise versa as
shown in Figure 2.7.4.

The encoder wheel typically makes one revolution for every revolution of the motor or the
wheel may be at a geared rotation ratio with respect to the motor. Therefore, the frequency of
the digital signal coming from the QEPA and QEPB outputs varies proportionally with the
velocity of the motor. For example, a 2000-line encoder directly coupled to a motor running
at 5000 revolutions per minute (rpm) results in a frequency of 166.6 KHz, so by measuring
the frequency of either the QEPA or QEPB output, the processor can determine the velocity
of the motor.
Figure 2.7.4. QEP Encoder Output Signal for Forward/Reverse Movement
eQEP Inputs
The eQEP inputs include two pins for quadrature-clock mode or direction-count mode, an
index (or 0 marker), and a strobe input.
QEPA/XCLK and QEPB/XDIR
These two pins can be used in quadrature-clock mode or direction-count mode.
Quadrature-clock Mode
The eQEP encoders provide two square wave signals (A and B) 90 electrical degrees out
ofphase whose phase relationship is used to determine the direction of rotation of the input
shaft and number of eQEP pulses from the index position to derive the relative position
information. For forward or clockwise rotation, QEPA signal leads QEPB signal and vice
versa. The quadrature decoder uses these two inputs to generate
quadrature-clock and direction signals.

Direction-count Mode
In direction-count mode, direction and clock signals are provided directly from the external
source. Some position encoders have this type of output instead of quadrature output. The
QEPA pin provides the clock input and the QEPB pin provides the direction input.
eQEPI: Index or Zero Marker
The eQEP encoder uses an index signal to assign an absolute start position from which
position information is incrementally encoded using quadrature pulses. This pin is connected
to the index output of the eQEP encoder to optionally reset the position counter for each
revolution. This signal can be used to initialize or latch the position counter on the
occurrence of a desired event on the index pin.
iii. Two Channel Optical Encoders
Figure-2.7.5 Two channel Quadrature Encoder pulse
Description
The HEDM-5605 is high performance, low cost, two channel optical incremental encoders is
shown in figure-2.7.5. These encoders emphasize high reliability, high resolution, and easy
assembly.
Each encoder contains a lensed LED source, an integrated circuit with detectors and output
circuitry, and a codewheel that rotates between the emitter and detector IC. The outputs of
the HEDM- 5605 are two square waves in quadrature. This index output is a 90 electrical
degree, high true index pulse that is generated once for each full rotation of the codewheel.
The HEDS series utilizes metal codewheels, while the HEDM series utilizes a film
codewheel allowing for resolutions to 1024 CPR.
These encoders may be quickly and easily mounted to a motor. For larger diameter motors,
the HEDM-5605 feature external mounting ears. The quadrature signals and the index pulse
are accessed through five 0.025 inch square pins located on 0.1 inch centers.

Working Operation
The HEDM-5605 translates the rotary motion of a shaft into either a two- digital output. As
seen in the figure-2.7.6, these encoders contain a single Light Emitting Diode (LED) as its
light source. The light is collimated into a parallel beam by means of a single polycarbonate
lens located directly over the LED. Opposite the emitter is the integrated detector circuit.
This IC consists of multiple sets of photodetectors and the signal processing circuitry
necessary to produce the digital waveforms. The codewheel rotates between the emitter and
detector, causing the light beam to be interrupted by the pattern of spaces and bars on the
codewheel. The photodiodes, which detect these interruptions, are arranged in a pattern that
corresponds to the radius and design of the codewheel. These detectors are also spaced such
that a light period on one pair of detectors corresponds to a dark period on the adjacent pair
of detectors. The photodiode outputs are then fed through the signal processing circuitry
resulting in A, A, B and B. Comparators receive these signals and produce the final outputs
for channels A and B. Due to this integrated phasing technique, the digital output of channel
A is in quadrature with that of channel B (90 degrees out of phase). In the HEDS-5540 and
5640, the output of the comparator for I and I is sent to the index processing circuitry along
with the outputs of channels A and B.
Figure-2.7.6 Block diagram for QEP (HEDM-5605)
The final output of channel I is an index pulse PO which is generated once for each full
rotation of the code wheel. This output PO is a one state width (nominally 90 electrical
degrees), high true index pulse that is coincident with the low states of channels A and B.

8.3. CONNECTOR DETAILS
Quadrature Encoder Pulse Sensor
Figure2.7.7-9-Pin ‘D’connector for QEP Sensing
ii. Optical Encoder Sensor
Figure-2.7.8, 9 pin “D” Connector for Optical Encoder Sensing
PIN Details
1. Cathode
2. Anode
3. Collector
4. Emitter
5. No Connection
6. No Connection
7. No Connection
8. No Connection
9. No Connection
CHA
INDEX CHB
1 2 3 4 5
+VCC
(+5V)
5 4 3 2 1
6789
PIN NO1 - GND
PIN NO2 - INDEX
PIN NO4 - +VCC
PIN NO3 - CHA
PIN NO5 - CHB
GND
512 PULSE / REVOLUTION
HEDS 5645
9 PIN `D' CONNECTOR
PIN NO. 6,7,8,9 = No Connection
987
5432
6
1

9. FREQUENCY TO VOLTAGE CONVERTER
The square wave of speed sensor output is feed to frequency to voltage converter circuit. The
XR4151 can beused as afrequencyto voltageconverter.Thevoltageappliedto comparator input
Pins6 and 7 should not be allowed to go below ground by more then 0.3V. The input frequency
range is 0 to 10KHz and corresponding voltage output level is -10mV to -10V.
In our module set the frequency to voltage converter with Max. output of 2.5V at rated motor
speed of 1500 rpm.

10. GENERAL INSTRUCTION
Precaution
1. You are working with IPM based power module, in case of over voltage/under
voltage/over current/ over temperature occurs, shut down LED' SD' will glow. The
Gating signals to the inverter switches will be switched off. Adjust the input voltage to
minimum position. Then press the reset switch, shut down LED 'SD' will gets turned
OFF. Then again start the experiments.
2. If CRO is used to the output voltage wave forms it is recommended to isolate the input
AC.
Measurement
1. Measure the DC Link voltage from the voltmeter.
2. Check the pulse sequences PWM1 to PWM6 at the test points of IPM based module
(PEC16DSMO1) by using CRO.
1 2 33. Observe the current and voltage wave forms from the test points for I (R),I (y), I (B) and
DCV with respect to ground.
4. Measure the frequency to voltage converter output across the test point ‘N’ and GND.
5. Shut down LED 'SD' indicates whether the fault has occurred (over voltage /under
voltage/over current/ over temperature ) or not.
Note
1. Initially keep the MCB switch in 'OFF' position.
2. Connect the three-phase AC supply across the terminals R, Y & B.
3. The "FEED BACK SIGNALS" and "IGBT PWM INPUTS" connectors of IPM modules
are connected to Controller by using 26 pin and 34 pin FRC connectors respectively.
4. Connect the external Rheostat (470S/2A) across the banana connectors BR1 and BR2.

INTELLIGENT POWER MODULE Model No : PEC16DSMO1

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