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Registered Member #162
Joined: Mon Feb 13 2006, 10:25AM
Location: United Kingdom
Posts: 3140
just wanted to add my admiration! a very nice layout / construction. I like the way you minimise inductance I've had wires going through heatsinks to attempt the same, not very good good luck (though you need it less than most of us!) and keep us posted.
Registered Member #176
Joined: Tue Feb 14 2006, 09:35PM
Location:
Posts: 44
Hi Steve,
Nice work looks very professional. Are those lytics in half a RS equipment enclosure? I have seen something simular shappped with the cut outs on the side in the RS cat.
At least some one is finally using some of the lytics I had and a big coil is been built!
How are you connecting the gate drive to the bricks?
Registered Member #30
Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706
Hi Adam
Yes it's an old case from RS I got it from a junk pile at the uni. It seems like a weird way to mount the caps, but it actually worked out easier than buying the big oversized capacitor clamps and cutting big holes in a piece of sheet metal.
I'm using outboard gate drivers, they will connect to the IGBTs via about 4" of ribbon cable with alternate cores connected to gate and emitter to give extra low inductance... I don't do the I word man It turned out too much of a hassle to mount the drivers straight to the IGBTs, considering I want to use the same gate driver boards with CM600s in the future, and their gate terminals are in totally different places.
The drivers will connect back to the PLL unit using Cat5 network cables with the little 8-way modular jacks because they're cheap.
Registered Member #176
Joined: Tue Feb 14 2006, 09:35PM
Location:
Posts: 44
Hi Steve,
**digs out notebook**
Its a nice idea and all your layouts look really low inductance. Do you apply the math to work out the actual inductance of the layout? I tried it on the one I will discuss below but I got really small numbers and decided that those could not be right!
I have all the parts to still build a big CM600 bridge. The modules would be built with smds and inside a can with BNC connectors to connect them to the driver and would bolt direct to a CM600.
The layout I decided on was simular to yours but imagine it been on its side with the bridge flat.
The bridge was a huge long length of heatsink like on your OLTC2 the same stuff. The bricks would have a laminated bus scheme but the caps on there side and bolted in mid air across the laminate. You end up with 6 electrolics across a low inductance laminate bus scheme. The DC in would bolt direct to a IRPACK SCR moudle the dual ones. Eveything lies flat with the caps horizonal to the bricks that are vertical.
The whole system would of been nice to build with lots of thick copper busbar. I also designed in a method of mounting polyester excel decoupling caps in there.
I still have 6 brand new cm600s and most of the design work done on the bridge. And I think I have a tray of caps left.
Registered Member #30
Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706
Hi Adam
No I don't calculate the inductance. I just know that the less area enclosed by the loop that the current flows in (ie the closer together the conductors are) the better. It doesn't really take much more effort to make a low inductance layout than an ordinary one.
If you want to build a 600A bridge for "Team Odin" you would be more than welcome! We could fire it up at Cambridge sometime. I think they can bring in 400V three phase power for us without too much hassle.
Registered Member #176
Joined: Tue Feb 14 2006, 09:35PM
Location:
Posts: 44
Steve Conner wrote ...
Hi Adam
No I don't calculate the inductance. I just know that the less area enclosed by the loop that the current flows in (ie the closer together the conductors are) the better. It doesn't really take much more effort to make a low inductance layout than an ordinary one.
If you want to build a 600A bridge for "Team Odin" you would be more than welcome! We could fire it up at Cambridge sometime. I think they can bring in 400V three phase power for us without too much hassle.
Registered Member #188
Joined: Thu Feb 16 2006, 05:18PM
Location:
Posts: 67
Wow, looks nice. Though i would do something about getting better isolation barriers, i always like to have at least 8mm for anything line-connected (well, might be because im currently doing PCB layouts for off-line SMPS things). So id use optos with 10.6mm lead spacing (like PC817 or CNY81) or just bend your standard DIP to this larger spacing. To save space, use 4-pinned ones, also reduces the chance of EMI pickup on the base lead (can be a large problem in noisy environments).
Registered Member #30
Joined: Fri Feb 03 2006, 10:52AM
Location: Glasgow, Scotland
Posts: 6706
Update: I finished the gate driver layout and also revised the main PLL board layout, and ordered a batch of each from Gold Phoenix. I expect to get 8 PLL boards and about 30 gate drivers.
Robert: I chose to use 6-pin optos because they bring the base lead out, so I could tie it to the emitter with a resistor in an attempt to make it less sensitive to EMI. :P And because 4N35s are pretty cheap I suppose.
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Odin The All-Fragger: a large DRSSTC
I got it from a junk pile at the uni. It seems like a weird way to mount the caps, but it actually worked out easier than buying the big oversized capacitor clamps and cutting big holes in a piece of sheet metal.
It turned out too much of a hassle to mount the drivers straight to the IGBTs, considering I want to use the same gate driver boards with CM600s in the future, and their gate terminals are in totally different places.