PREFACE

PEC16M5 is a reference manual for IGBT/MOSFET chopper control circuit. This manual
briefly explains each and every section present in the module. Moreover the step-by-step
procedure to perform the various experiment using this trainer are given. We hope that this
module will help in setting up a good power electronics laboratory in a simple manner. It is a
laboratory type module, so power electronic staff can teach the students easily with the 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
this module. This is very helpful to solve the occurrence of minority 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,
Department of Power Electronics
Vi Microsystems Pvt. Ltd.,
Plot No. 75, Electronics Estate,
Perungudi, Chennai-600 096.
India
Phone: 91-44-2496 3142, 5201 5899.
E-mail: rnd@vimicrosystems.com
IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
1. INTRODUCTION

Power Electronics is the technology of converting electric power from one form to another using
electronic power devices. In power converters, the power semiconductor devices functions as a
static switch which operate without contacts. Chopper is one such converter, which converts
constant DC voltage to variable DC voltage. The switch used for chopper operation may be a
MOSFET or an IGBT. This text manual explains in detail about the chopper control circuit
trainer module (PEC16M5)

2. ABOUT OUR TRAINER

The following are the description of our trainer module.

2.1 PICTORIAL VIEW

Chopper Control module consists of the Following units

1. Chopper Mode Selection.

2. Voltage Adjustment.
3. Switching Frequency Adjustment.
4. Carrier Generation unit.
5. Reference Voltage
6. PWM comparator Unit
7. Pulse ON/OFF switch
8. Logic Gates
9. 9 - Pin connector.
Vi Microsystems Pvt. Ltd., [1]
IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
2.2 SPECIFICATIONS

Transformer - 230 / 15V

Multiple DC output - +15V, -15V

IC Details

TLO84 - Operational Amplifier

LM311N - PWM Comparator

CD4081 - AND gate

CD4011 - NAND gate

PAL16L8 - Programmable Array Logic

74LS04 - Buffer.

Vi Microsystems Pvt. Ltd., [2]

IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
2.3 FRONT PANEL VIEW

Vi Microsystems Pvt. Ltd., [3]

IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
2.4 FRONT PANEL DESCRIPTION

PEC16M5 trainer module comprises of the following.

1) A high frequency carrier generation unit generates triangular carrier with

frequency range from 2.5KHz to 4KHz.

2) Reference voltage is obtained by the separation of input DC voltage in the

inverting and non inverting amplifier circuit.

3) Chopper control mode of operation is selected using a switching knob. The

selection is made between the following.

1 - Single quadrant operation

2 - Two quadrant operation
3 - Four quadrant unipolar operation
4 - Four quadrant bipolar operation

4) Duty cycle adjustment knob is used to adjust the duty cycle ratio from minimum
to maximum.

5) Switching frequency adjustment knob is provided to change the carrier

frequency from minimum to maximum.

6) The carrier signal and +ve Reference voltage is compared in the comparator unit
to generate +ve going PWM pulse and similarly carrier signal is compared with
-ve reference voltage to generate a negative going PWM pulse.

7) PWM pulse from comparator is given a phase shift in the logic gates. So as to
avoid switching ON of devices in the same leg at the same time.

8) PWM pulse from Logic gates are taken out through 9 pin connector.

9) Pulse ON/OFF switch is used to release the pulse from the logic gates to the
power module.

10) Power to the trainer module is controlled by ON/OFF press button. LED
indicates power ON and OFF to the module.

Vi Microsystems Pvt. Ltd., [4]

IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Front Panel Description

SWITCH POSITION GATING SIGNALS To

1 T2
2 T1 & T2
3 T1, T2 & T3, T4
4 T1, T4 & T3, T2

Test Point Description

T1 - To observe inverting amplifier output.

T2 - To observe non-inverting amplifier output.

T3 - To observe positive reference voltage.

T4 - To observe negative reference voltage.

T5 - To observe high frequency carrier signal.

PWM1 - To observe positive PWM pulse.

PWM2 - To observe negative PWM pulse.

GND - Digital ground.

Pulse 1 - To observe PWM pulse to switch 1.

Pulse 2 - To observe PWM pulse to switch 2.

Pulse 3 - To observe PWM pulse to switch 3.

Pulse 4 - To observe PWM pulse to switch 4.

Vi Microsystems Pvt. Ltd., [5]

IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
2.5 CONNECTOR DETAILS

9 pin female socket connector

Pin Details

1 PWM1
2 PWM2
3 PWM3
4 PWM4
5 GND
6 NC
7 NC
8 NC
9 NC

Vi Microsystems Pvt. Ltd., [6]

IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
3. HARDWARE DESCRIPTION

Vi Microsystems Pvt. Ltd., [7]

IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
3.1 CHOPPER CONTROL CIRCUIT

Components On PEC16M5 Circuit

Component Location
Op-Amp (TL082) 3B

Carrier Generator (TL084) 4B

Comparator (LM311) 3F, 4F

NAND gate (4011) 3I

AND gate (4081) 3L

Buffer (74LS04) 4L

PAL (16L8) 4I

26-pin FRC connector 6E, 6F, 6G

5 pin Unicon Connector 1D, 1E

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
3.2 BLOCK DIAGRAM

Block Diagram of PEC16M5 consists of

i. Inverting Amplifier
ii. Non-inverting Amplifier.
iii. Comparator.
iv. Carrier Generator.
v. Programmable Array logic.
vi. Logic Gates.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Inverting Amplifier

In the Inverting amplifier circuit, output voltage is fedback to the inverting terminal of Op-Amp.
The output voltage obtained is opposite to that of the input voltage and is an amplified voltage.

Non-Inverting Amplifier

In the non-inverting amplifier circuit output voltage is in phase with the input and is an amplified
output voltage.Thus the positive and negative reference wave for PWM pulse generation has been
obtained from the inverting and non-inverting amplifier circuits.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Carrier Signal Generation

Carrier signal is generated using the above shown operational amplifier based carrier generation
circuit. Carrier generation circuit consists of level comparator followed by an integrator circuit.
Output of A1 is a square wave and output of A2 is a triangular wave. Output of A2 is feedback
to A1 through a voltage divider circuit.

Comparator

A Comparator is a circuit which compares signal voltage applied to one input of an OP-AMP
with a known reference at the other input. In the above comparator circuit, Vc is applied to the
non-inverting input and C is applied to the inverting input. The two signals are compared and
PWM signal is generated. The reference voltage Vc is compared with the triangular carrier
signal.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Logic Gates

Programmable Array Logic PAL16L8

Program for chopper mode selection is stored in the PAL IC. When the mode of operation is
selected, the respective chopper operation logic is enabled and generates respective PWM pulse
signal to the power module is generated PAL consists of an array of gates whose operation is
controlled by programming. The PWM pulse from PAL IC is given to the AND gate and is
ANDed with the +5V signal. The AND logic is used for pulse release operation. +5V is supplied
through the SPDT switch. When pulse ON/OFF switch is switched ON, +5V is applied. The
PWM pulse is ANDed with +5V and we get buffered PWM pulse output. If the switch is in OFF
position, zero voltage appears to the AND gate and so PWM pulse output does not appear at the
buffer output.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
4. CHOPPER CIRCUIT USING MOSFET/IGBT

4.1 CHOPPER CONTROL MODULE

This module generates the gating signals required for (i) single quadrant (ii) Two quadrant
chopper (iii) Four Quadrant Chopper circuits. The gating signals are generated by comparing
a triangular carrier with a reference dc control voltage level. The carrier frequency can be
selected between two limits minimum (2.2 KHz) and a maximum (4.2 KHz). Within the selected
maximum frequency it is possible to vary the carrier frequency. The power supply required for
the control circuitry is built in. Test points are provided in the front panel to study the operation
of various stages in the control circuitry.

The gating signals are terminated at 9 pin D connector and is to be connected to chopper module
through the cable provided.

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. Choppers are also used
in DC voltage regulators. The circuit configuration of a chopper converter can be designed either
to step down the input voltage level or to step up the input voltage to a higher voltage level.
Accordingly the chopper is called as step down or step up chopper. The basic principle of step
down chopper is explained in the following.

Chopper Circuit Load Voltage and Current Waveform

4.2 STEP DOWN CHOPPER

The principle of operation of the chopper is explained by the circuit of fig. The switch SW is a
semiconductor device. When the switch is ON for a time tON, the input voltage Vs appears
across the load. If the switch is OFF for a time tOFF, the voltage across the load is zero. The
waveforms of the output voltage and load current for resistive load is shown in fig.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Neglecting the voltage drop across the switch, the average output voltage Vo is given by

(4.1)

(4.2)

(4.3)

(4.4)

(4.5)

(4.6)

(4.7)

Where,

Theoretically the duty cycle ratio D can be varied from 0 to 1 by varying tON and tOFF. Thus the
output voltage VO can be varied from 0 to Vs by controlling D and hence the power flow can be
controlled. When the chopping frequency f is kept constant and the on time tON is varied, the
width of the pulse is varied and the chopper is known as constant frequency chopper. This type
of control is known as Pulse Width Modulation (PWM) control.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Operation with inductive (R-L) Load

When the load is inductive in nature (R-L), another semiconductor device (a diode - Df) is to be
added to the basic circuit as shown in fig. The diode is commonly known as the freewheeling
diode.

Chopper with inductive load

Waveform of load voltage and current with inductive load

When the switch SW is turned on for a time tON, the input voltage Vs appears across the load, The
diode Df is reverse biased. The load current starts building up from the instant when switch is
turned on. The growth of the current is exponential because of the inductance L. The waveforms
of Load voltage V0 and current i1, are shown in fig. The current i1(t) when SW is ON is given by

(4.8)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
for o # t # Ton (=DT), At the end of t = tON, the load current becomes

(4.9)

At the instant when SW is turned off, the current i1(tON) = I2, cannot instantly fall to zero,
because of the presence of the inductance L. The decay of current causes an induced voltage
across the inductance. Because of this voltage, the diode DF is forward biased and causes the
current flow to continue. The term "Free wheeling" is commonly used to describe the flow of
current in this manner without being caused by a voltage source, but solely due to the stored
energy in the inductance. The purpose of the diode DF is to provide the freewheeling path when
SW is turned off. Therefore the turning OFF of SW automatically causes the turning ON of DF.

The decay of current I2 continues as long as SW is off. The current decays exponentially from
the initial value of I2 (When SW is turned OFF) as long as SW remains OFF. The current in this
period is given by

(4.10)

for 0 # t # tOFF [ = (1-D) T]. The values of current at the time instants when SW is turned ON I1
and turned OFF I2, are the steady state values after a number of switching cycles have been
passed. If the load inductance is very small or the duty cycle ratio is very small the value of I1
will be zero, as shown in fig. The chopper is then said to operate in the discontinues current
mode.

Chopper with Back-emf (DC Motor) Load

The chopper with back-emf load such as a DC motor is shown in Fig. The voltage and current
waveforms will be similar to that shown in fig. The current during SW is on, is given by (Under
continuous current mode).

(4.11)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
When SW is OFF, and DF is ON, the current

(4.12)

Where E - the back emf.

4.3 FOUR QUADRANT CHOPPER

The chopper circuits described above, can operate only in two quadrants of the v0-i0 plane. The
chopper circuit shown in figure can operate in all the four quadrants of the vo-i0 plane shown in
figure. That is the output voltage and current can be controlled both in magnitude as well as in
direction. Therefore the power flow can be in either direction. 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.

Four quadrant chopper circuit.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5

Four quadrant of Vo, io plane.

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.

The four quadrant chopper with four switching devices where diodes are connected in antiparallel
with the switching devices is also referred to as a full-bridge converter topology. The input to
the full bridge converter is a fixed magnitude dc voltage Vdc. The output of the converter can be
a variable dc voltage with either polarity. This circuit is therefore called as the four quadrant
chopper circuit (or a dc-to-dc converter). In a full bridge converter, when a gating signal is given
to a switching device either the switching device or the diode only will conduct depending on the
direction of the output load current. The full bridge converter consists of two legs; Leg-1
comprising the switches T1, T2 and their associated antiparallel diodes D1 and D2 Leg-2
comprising switches T4, T3, D3 and D4. While operating the converter, the two switches in the
same leg are not to be switched simultaneously, since this would cause a short circuit across the
dc supply. That is only one of the device in a leg will be in the ON state and the other will be in
its OFF state. In practice both the devices in a leg are made to be in OFF state for a short time
interval to avoid short circuiting of the dc input.

Switching Modes of Four-Quadrant Chopper

The switches in the four-quadrant chopper can be switched in two different modes such that

i. The output voltage swings in both directions; i.e., from +Vdc to-Vdc. This mode
of switching is reffered to as PWM with bipolar voltage switching.

ii. The output voltage swings either, from zero to +Vdc or zero to -Vdc. This mode
of switching is reffered to as PWM with unipolar voltage switching.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
In the bipolar voltage switching mode the switches (T1, T4) and (T3, T2) are treated as two switch
pairs and each pair are turned on and turned off simultaneously. In the unipolar voltage
switching mode, the switches in each leg are controlled independently.

Operation of the Four-quadrant chopper with bipolar Voltage Switching.

The operation of the circuit as a four quadrant chopper with bipolar voltage switching is
explained, referring to the circuit diagram. When the switches T1 and T4 are turned ON by
applying gating signals simultaneously, the load voltage is Vdc with terminal `A' positive and
the load current iL flows in the direction of A to B. The load current flows from source through
T1, the load circuit and T4. Now, suppose T1 and T4 are turned OFF by removing the gating
signals. Because of the load inductance, the current cannot change instantaneously. The load
current iL will now start flowing through D3, the dc source and D2. The load voltage vL will now
be -Vdc, since the conduction of the diode D3 will connect the load terminal B to the (+)ve
terminal of the source. As the load voltage is negative and the current is still positive, the power
is negative. The power now flows from the load to the source. The stored energy in the load
inductance is now being returned to the source. This corresponds to the operation of chopper
circuit in the fourth quadrant. This operation in the fourth quadrant will continue as long as the
current is positive.

When the current passes through zero, the devices T3 and T2 can be turned on, and the load
current becomes negative. The load current now passes through T3 and T2 with current direction
in the load as from B to A. This brings the operation of the chopper in the third quadrant.
Turning off of T3 and T2, will bring in the conduction of the diodes D1 and D4 and the operation
of the chopper circuit in the second quadrant.

The operation of the chopper in the first and third quadrant corresponds to power flow from the
source to the load, and is considered to be forward power flow. The operation in fourth and
second quadrant corresponds to reverse power flow (power flows from the load to the source).
The relevant waveforms showing the operation of the full bridge converter in all the four
quadrants are assuming that the load is inductive.

Operation of the Four-quadrant chopper with unipolar voltage switching.

Inspection of the chopper circuit of fig. shows that regardless of the direction the load current iL,
the load voltage vo is zero if T1 and T3 are both on. Similarly vo = 0, if T2 and T4 are both ON.
This property is utilised to improve the output voltage waveform.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5

Load Voltage and Current with inductive Load

Load Current iL>0 (Positive)

Load Voltage and Current with inductive load

Load Current iL<0 (negative)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
When T1 and T4 are turned on, the load voltage vo is +Vdc with terminal A positive with respect
to terminal B, and the load current flows from the source to the load. The current path being,
from the dc source through T1, the load circuit, T4 and back to the dc source. If T4 is now turned
off, the load current will flow through the diode D3 and T1. The voltage across the load is zero,
with the direction of the load current remaining the same. If T3 is switched on when T4 is turned
off the current would still flow through D3 as T3 cannot conduct current in the reverse direction.
Instead of turning off T4, T1 is turned off, the load voltage vo is again zero, but the current would
now flow through T4 and D2. In either case, the load current is said to be freewheeling. This
corresponds to the operation of the chopper in the first quadrant.

When the load current becomes zero, the switches, T3 and T2 can be turned on. The load voltage
VL and current iL becomes negative. Switching off of T2 (or T3) and turning ON of T1 (or T4) will
make the current to freewheel through D1 and T3 (D4). Similarly switching FF of T3 and turning
ON of T4 will make at to free wheel through T2 and this corresponds to the operation of chopper
in the third quadrant. The voltage and current waveforms with unipolar voltage switching is
shown in the Fig with unipolar switching. Operation in second and fourth quadrant would be
possible only with back emf load such as a dc motor.

Voltage and Current with Unipolar Voltage Switching Inductive Load.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Generation of Gating Signals for the Four Quadrant Chopper.

The gating signals for the switches in the four-quadrant chopper are derived by comparing a
triangular carrier wave with a control voltage level.

Gating Signals for bipolar voltage switching.

For bipolar voltage switching the devices (T1 and T4) are switched ON/OFF simultaneously.
When this pair of switches are OFF the other pair of switches T3 and T2 are switched ON and
vice-versa. The gating signals are generated by comparing a switching frequency triangular
waveform Vtri with the control voltage Vc. The pulse generated when Vc > Vtri are used to turn
ON T1 and T4. The complementary pulses are used to, turn ON T3 and T2. The waveform shows
the generation of the gating signals. The control voltage Vc is varied from -Vtri to +Vtri. When
Vc is (+)ve, the duty cycle ratio for the switches T1 and T4 is greater than 50% and the average
output load voltage will be (+)ve. When VC (-)ve, the duty cycle ratio for T3 and T2 will be more
than 50% and the average output voltage will be (-)ve.

Generation of Gating Signals

When Vc = 0, the switches T1, T4 and T3 and T2 are switched for equal interval of time. The
output voltage will then be zero.

The duty cycle ratio for the switch pair T1 and T4 is

(13)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
and duty cycle ratio for the switch pair T3 and T2 is

(14)

and the average output dc voltage is given by

(15)

Gating Signals for Unipolar voltage Switching:

The generation of gating signals for unipolar voltage switching is shown in the waveforms Fig.
The triangular carrier waveform is compared with the control voltage (+)vc and -vc. The pulse
generated by comparing +vc with triangular carrier is used to turn ON T1 and its compliment is
used to turn ON T2. The pulse generated by comparing -vc with triangular carrier is used to turn
on T3 and its complement is used to turn ON T4. The control voltage vc varies from zero to +Vtri.

Generation of gating signals for unipolar voltage switching.

The block diagram schematic of the gating circuit for the chopper is shown in Fig. It consists of
a triangular carrier generation whose frequency is adjustable. The gating signals for the single
quadrant, two quadrant and four quadrant choppers are obtained by comparing the appropriate
control voltage signal vc with the triangular carrier, and the appropriate signals are selected
through the mode selection switch. The comparator output signals are applied to high speed opto
isolator for the necessary isolation between the control circuit and the power circuit. The rising
edges of the gating signals for the devices on the same leg are delayed to an extent of the turn-off
time of the devices to avoid possible short circuit on the dc supply. The gating signals are then
applied to the gate driver IC IRF2110. A single IRF 2110 can drive two MOSFETs/IGBTs in
the same leg. The details of IRF 2110 is given in Appendix-I.
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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
4.4 MOSFET / IGBT POWER MODULE ( PEC16M2/M3)

This module consists of 4 IGBTs/MOSFETs. The voltage and current ratings of the IGBTs are
600V and 8A respectively. The dc power supply required for conducting various experiments
is built-in. The dc power supply is of 24V, with a maximum current rating of 2A.

The terminals of all the four IGBTs/MOSFETs are brought out to banana connectors mounted
at the front panel. Various power converter configurations can be made by proper
interconnection of the IGBT terminals at the front panel. An RC snubber circuit is provided for
each devices to provide protection against dv/dt. The mimic diagram showing the
interconnection of the IGBT terminals is screen printed on the front panel. The dc link voltage
is obtained through a step-down transformer and a full-wave diode bridge rectifier. A mains
power switch (with indicator) is provided to switch ON or OFF ac power (230V) to the input
transformer. This will also provide ±15V dc supply to the gate Driver IC IRF2110.

The gating signals from the control module is to be connected at the 9 pin D connector through
the signal cable provided. The gating signals are isolated from control power supply by means
of high-speed opto couplers. The isolated gating signals are then applied to the IGBT Driver IC,
IRF 2110, Two such Driver Ics are used; one driver IC provides gating signals to the devices in
one leg. Each IGBT can be used independently to study the switching characteristics or it may
be inter connected with others depending on the required converter topology.

4.4.1 METAL-OXIDE-SEMICONDUCTOR FIELD EFFECT

TRANSISTORS:(MOSFETs)

The circuit symbol of an n-channel MOSFET is shown in Figure. It is a voltage controlled

device, as is indicated by the i-v characteristics shown in Figure. The device is fully on and
approximates a closed switch when the gate-source voltage is below the threshold value, VGS(th).
The idealized characteristics of the device operating as a switch are shown in Figure.

N channel MOSFET
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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Metal-oxide-semiconductor field effect transistors require the continuous application of a gate-
source voltage of appropriate magnitude in order to be in the on state. No gate current flows
except during the transitions from on to off or vice versa when the gate capacitance is being
charged or discharged. The switching times are very short, being in the range of a few tens of
nanoseconds to a few hundred nanoseconds depending on the device type.

The on-state resistance rDS(on) of the MOSFET between the drain and source increases rapidly
with the device blocking voltage rating. Because of this, only devices with small voltage ratings
are available that have low on-state resistance and hence small conduction losses.

Metal-oxide-semiconductor field effect transistors are available in voltage ratings in excess of

1000V but with small current ratings and with up to 100 A at small voltage ratings. The
maximum gate-source voltage is ±20V, although MOSFETs that can be controlled by 5-V signals
are available.

4.4.2 INSULATED GATE BIPOLAR TRANSISTORS

The circuit symbol for an IGBT is shown in Figure and its i-v characteristics are shown in Figure.
The IGBT's have some of the advantages of the MOSFET, the BJT, and the GTO combined.
Similar to the MOSFET, the IGBT has a high impedance gate, which requires only a small
amount of energy to switch the device. Like the BJT, the IGBT has a small on-state voltage even
in devices with large blocking voltage ratings (for example, Von is 2-3V in a 1000-V device).
Similar to the GTO, IGBTs can be designed to block negative voltages, as their idealized switch
characteristics shown in Figure indicate.

IGBT

Insulate gate bipolar transistors have turn-on and turn-off times on the order of 1 :s and are
available in module ratings as large as 1700V and 1200A., Voltage ratings of up to 2-3kV are
projected.
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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
i. PICTORIAL VIEW

The IGBT/MOSFET power module consists of the following units

1. 24VDC Power ON/OFF switch.

2. Reset Push button
3. IGBT driver unit
4. Dead time Generation unit
5. PWM Isolation Unit.
6. 9 - pin connector
7. IGBT/MOSFET power circuit.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Components On PEC16M2/M3 driver

Component Location
Opto-isolator (A4506) 2B, 3B, 4B, 5B, 6B

Dead time generator (4098) 3E, 4E

Driver (1R2110) 2J, 5J

Amplifier (TL082) 2G, 5D

AND gate (4081) 5G

Inverter (4584) 3D, 4D

Flip Flop (4027) 3G, 4G

5 pin RMC connector 3A, 4A

16 pin FRC connector 3L, 4L

ii. SPECIFICATION

Transformer = 230V / 24V AC and 230V / 15V AC

Maximum Load Current (Ioc) = 2A

Device Specification

MOSFET - IRF840

IGBT - IMBH60T

IC - Details

Dead Time Generator - CD4098

Optoisolator - A4056

Driver - IR2110

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
iii. FRONT PANEL VIEW

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iv. FRONT PANEL DESCRIPTION

The front panel of IGBT / MOSFET power module consists of the following.
1. Power control to the power module is made through the power ON/OFF press
button.

2. LED is to indicate that the current level has exceeded the protective level. System
is reset using the reset press button. After Reset, LED goes OFF.

3. PWM pulse from control module are connected to the power module through the
9 pin female socket connector.

4. PWM pulse to the power module are isolated from the power circuit in the PWM
isolator.

5. Dead time generator, generates dead time to PWM pulses in order to avoid
switching ON devices in the same leg, at the same time.

6. IGBT driver IC provides PWM pulse to the Gate-Emitter of the power circuit.

7. SPDT (SW1) ON/OFF switch is to control DC Voltage to the Power circuit.

Power circuit consists of four switches (IGBT/MOSFET).

Test Point Description

PWM 1 - To observe PWM pulse to switch 1.

PWM 2 - To observe PWM pulse to switch 2.

PWM - To observe PWM pulse to switch 3.

PWM 4 - To observe PWM pulse to switch 4.

GND - Digital ground.

T5, T6, T7, T8 - To observe isolated PWM pulse.

AGND - Analog ground.

T1 - Positive pulse to switch 1.

T2 - Negative Pulse with dead time to switch 2.

T3 - Negative pulse to switch 3.

T4 - Positive pulse with dead time to switch 4.

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v. HARDWARE DESCRIPTION

Block Diagram :

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Pwm Isolation Section

PWM input is given to the driver circuit through the 5 pin RMC connector. The pulses given are
PWM1, PWM2, PWM3, PWM4 and fault. The fault signal gets enabled any external fault aries
and generates a shutdown signal to the driver IC. PWM signal undergoes isolation from high
power in the opto isolator. Opto isolator circuit is shown below.

The isolated PWM signal is inverted using inverter IC 4584.

Dead time generator

Dead time is generated so as to prevent switching ON of switches in the same leg at the same
time. Dead time generator circuit is shown below.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
A dead time generator has two 4098 ICs. PWM pulse from the opto-isolator is given as input to
the 4098. 4098IC generates a dead band between the Switching OFF of IGBT 1 and switching
ON of IGBT2. A dead band is a short period of time in which both the switch (IGBT/MOSFET)
in the same leg are switched OFF. This dead band generation is required to avoid switch ON of
IGBT2 when IGBTI is still conducting. If such cases occur it will result in short circuit of the
input DC supply voltage to the power circuit.

Current Sensing Section

Current Sensing section consists of an Op-amp and a flip flop. The current signal switches the
device is given to the Op-Amp to amplify the gain of the current signal. If the switching device
current crosses the current range of 1.5A to 2A (which is set using the Trimpot) the current signal
enables the flip-flop. The flip-flop enables the shutdown pin of the driver IC and thus stops the
PWM signal output.

Driver

The Driver IC has independent high and low side referenced output channels. The output drivers
feature a high pulse current buffer stage designed for minimum driver cross-conduction.
Propagation delays are matched to simplify usage for high frequency applications. The floating
Channel can be used to drive an n-channel Power MOSFET/IGBT in the high sign configuration
with which operates upto 500V. The Driver circuit is shown below.

5. INSTALLATION PROCEDURE
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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Before doing the installation check out the below mentioned apparatus.

# IGBT/MOSFET chopper control circuit (PEC16M5) Trainer kit.

# IGBT/MOSFET based power module (PEC16M2/M3).
# 9 pin cable.

DO’s

i. Ensure the fuses are in good condition.

ii. Switch ON the power.

iii. Ensure the test point waveforms with respect to GND.

iv. Ensure the input supply 24V AC, 50Hz signal.

v. Whenever doing the connections make sure that all switches are in OFF condition.

vi. Make the connections as per the connection procedure.

vii. Switch ON the power and SPDT switches.

viii. Do the experiment as per the experimental procedure.

DONT's

i. Don’t interchange the analog and digital ground points.

ii. Don’t check the PWM signal with analog ground (AGND)

iii. Don’t check the PWM signal from PWM isolator with digital ground (GND).

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
6. TEST POINT WAVEFORMS

Test Point Waveforms of PEC16M5.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Test Point Wave Forms of PEC16M2/M3

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
7. SERVICE TIPS

K Verify the test point waveforms with respect to GND.

K If all the test point waveforms cannot be viewed then multi output power supply
regulator IC 7815, 7915 may be fault.

K Check whether 24V AC input if it is not 24V step down Transformer may be fault.

Verify the output signal Component Details Remarks

Synchronize sine signal Step down Transformer Check and Replace, if it is
damaged.
Triangle signal at carrier TL-084 Check and Replace, if it is
generator output. damaged
PWM signal at Comparator LM311 Check and Replace, if it is
Output. damaged
Carrier signal at carrier CD4011 Check and Replace, if it is
OSC. Output. damaged
+ve, -ve pulse signal at CD4082 Check and Replace, if it is
AND gate output. damaged
All test point waveforms Regulator 7815,7915 Check and Replace, if it is
damaged

24V AC input P.N terminal 24V step down transformer Check and Replace, if it is
damaged

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
8. SAFETY PRECAUTIONS

Why is safety important?

Attention and adherence to safety considerations is even more important in a power electronics
laboratory than its required in any other undergraduate electrical engineering laboratories. Power
electronic circuits can involve voltages of several hundred volts and currents of several tens of
amperes. By comparison the voltages in all other teaching laboratories rarely exceed 20V and the
currents hardly ever exceed a few hundred milliamps.

In order to minimize the potential hazards, we will use dc power supplies that never exceed
voltages above 40-50V and will have maximum current ratings of 20A or less. Most of the time
we will use dc supplies of 20V or less and 1 A or less output current capability. However in spite
of this precaution, power electronics circuits on which the student will work may involve
substantially larger voltages (up to hundreds of volts) due to the presence of large inductances
in the circuits and the rapid switching on and off of amperes of current in the inductances. For
example a boost converter can have an output voltage that can theoretically go to infinite values
if it is operating without load. Moreover the currents in portions of some converter circuits may
be many times larger than the currents supplied by the dc supplies powering the converter
circuits. A simple buck converter is an example of a power electronics circuit in which the output
current may be much larger than the dc supply current.

Potential problems presented by Power Electronic circuits

1. Electrical shock may take a life.

2. Exploding components (especially electrolytic capacitors) and arcing circuits can cause
blindness and severe burns.
3. Burning components and arcing can lead to fire.

Safety precautions to minimize these hazards

i. General Precautions

* Be calm and relaxed, while working in Lab.

* When working with voltages over 40V or with currents over 10A, there must be
at least two people in the lab at all times.
* Keep the work area neat and clean.
* No paper lying on table or nearby circuits.
* Always wear safety glasses when working with the circuit at high power or high
voltage.
* Use rubber floor mats (if available) to insulate yourself from ground, when
working in the Lab.
* Be sure about the locations of fire extinguishers and first aid kits in lab.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
* A switch should be included in each supply circuit so that when opened, these
switches will de-energize the entire setup. Place these switches so that you can
reach them quickly in case of emergency, and without reaching across hot or high
voltage components.

ii. Precautions to be taken when preparing a circuit

* Use only isolated power sources (either isolated power supplies or AC power
through isolation power transformers). This helps using a grounded oscilloscope
and reduces the possibility of risk of completing a circuit through your body or
destroying the test equipment.

iii. Precautions to be taken before powering the circuit

* Check for all the connections of the circuit and scope connections before
powering the circuit, to avoid shorting or any ground looping that may lead to
electrical shocks or damage of equipment.
* Check any connections for shorting two different voltage levels.
* Check if you have connected load at the output.
* Double check your wiring and circuit connections. It is a good idea to use a
point-to-point wiring diagram to review when making these checks.

iv. Precautions while switching ON the circuit

* Apply low voltages or low power to check proper functionality of circuits.

* Once functionality is proven, increase voltages or power, stopping at frequent
levels to check for proper functioning of circuit or for any components is hot or
for any electrical noise that can affect the circuit’s operation.

v. Precautions while switching off or shuting down the circuit

* Reduce the voltage or power slowly till it comes to zero.

* Switch of all the power supplies and remove the power supply connections.
* Let the load be connected at the output for some time, so that it helps to discharge
capacitor or inductor if any, completely.

vi. Precautions while modifying the circuit

* Switch Off the circuit as per the steps in section v.

* Modify the connections as per your requirement.
* Again check the circuit as per steps in section iii, and switch ON as per steps in
section

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
vii. Other Precautions

* No loose wires or metal pieces should be lying on table or near the circuit, to
cause shorts and sparking.
* Avoid using long wires that may get in your way while making adjustments or
changing leads.
* Keep high voltage parts and connections out of the way from accidental touching
and from any contacts to test equipment or any parts, connected to other voltage
levels.
* When working with inductive circuits, reduce voltages or currents to near zero
before switching open the circuits.
* BE AWARE of bracelets, rings, metal watch bands, and loose necklace (if you
are wearing any of them), they conduct electricity and can cause burns. Do not
wear them near an energized circuit.
* Learn CPR and keep up to date. Your can save a life.

When working with energized circuits (while operating switches, adjusting controls, adjusting
test equipment), use only one hand while keeping the rest of your body away from conducting
surfaces.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
9. EXPERIMENTAL SECTION

EXPERIMENT - 1

AIM

To study the single quadrant chopper switching operation using PEC16M5 and PEC16M2/M3
module.

EQUIPMENT REQUIRED

i) PEC16M5 Trainer module.

ii) PEC16M2/M3 Trainer module.

iii) CRO.

iv) R - L Load.

FORMULA USED

Output voltage, V0 = DVS.

Where
D - Duty Cycle Ratio ton/T
ton - ON time.
T - Cycle Time [T = 1/f]

CIRCUIT DIAGRAM

Chopper Circuit

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
CONNECTION PROCEDURE

1) Connect P1 of 24V DC to P7 of IGBT2

2) Connect R-L load between P9 of IGBT2 and P8 of 24V DC.

3) Connect pulse output through 9 pin connector of chopper control module to 9 pin
connector of IGBT/MOSFET power module using a 9 pin cable.

EXPERIMENTAL PROCEDURE

1) Switch ON the power ON/OFF switch in the MOSFET/IGBT power module LED
glows. Press reset switch to reset the trainer module. LED switches OFF.

2) Switch ON the 24V DC ON/OFF switch (SW1).

3) Switch ON power ON/OFF switch of PEC16M5 trainer module.

4) Select the single quadrant chopper operation mode by setting the switching knob
at position 1.

5) Switch ON pulse ON/OFF switch to release the pulse to the power module.

6) Observe the test waveforms in the test points provided on trainer module.

7) Adjust the duty cycle adjustment knob from minimum to maximum and note
down the output DC voltage.

8) Adjust switching frequency adjustment knob from minimum to maximum and

note down the output DC voltage.

NOTE

Protection circuit is provided in the power module. When Load current increases above 1.5A to
2A the protection circuit automatically resets the power circuit, thus protecting the devices.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Table :1

Switching frequency = Hz

S.No ton(S) D = ton/T Measured Vo Calculated

(V) Vo(V)

Table :2

ton = S

S.No T(S) D = ton/T Measured Vo Calculated

(V) Vo(V)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
EXPERIMENT - 2

AIM

To study the two quadrant chopper operation using PEC16M5 and PEC16M2/M3 module.

EQUIPMENT REQUIRED

i) PEC16M5 Trainer module.

ii) PEC16M2/M3 Trainer module.

iii) CRO.

iv) R - L Load.

FORMULA USED

Output voltage, V0 = DVS.

Where
D - Duty Cycle Ratio tan/T
ton - ON time.
T - Cycle Time [T = 1/f]

CIRCUIT DIAGRAM

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
CONNECTION PROCEDURE

1) Connect P1 of 24V DC to P2 of IGBT1

2) Connect P4 of IGBT1 to P7 of IGBT2

3) Connect P8 of 24V DC to P9 of IGBT2

4) Connect R-L load between P4 of IGBT1 and P9 of IGBT2.

5) Connect pulse output through 9 pin connector of chopper control module to 9 pin
connector of IGBT/MOSFET power module using a 9 pin cable.

EXPERIMENTAL PROCEDURE

1) Switch ON the power ON/OFF switch in the MOSFET/IGBT power module LED
glows. Press reset switch to reset the trainer module. LED switches OFF.

2) Switch ON the 24V DC ON/OFF switch (SW1).

3) Switch ON power ON/OFF switch of PEC16M5 trainer module.

4) Select the two quadrant unipolar chopper operation mode by setting the switching
knob at position 2.

5) Switch ON pulse ON/OFF switch to release the pulse to the power module.

6) Observe the test waveforms in the test points provided on trainer module.

7) Adjust the duty cycle adjustment knob from minimum to maximum and note
down the output DC voltage.

8) Adjust switching frequency adjustment knob from minimum to maximum and

note down the output DC voltage. The current and voltage values both are
positive.

9) Switch OFF power supply to the power module.

10) Connect the load between P4 of IGBT1 and P3 and follow the same procedure as
above. Now voltage and current both are negative.

NOTE :

Protection circuit is provided in the power module. When Load current increases above 1.5A to
2A the protection circuit automatically resets the power circuit, thus protecting the devices.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Table :1

Switching frequency = Hz

S.No Ton D = ton/T Measured Vo Calculated

(S) (V) Vo(V)

Table :2

Ton = S

S.No Ton D = ton/T Measured Vo Calculated

(S) (V) Vo(V)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
EXPERIMENT - 3

AIM

To study the Four quadrant chopper unipolar switching operation using PEC16M5 and
PEC16M2/M3 module.

EQUIPMENT REQUIRED

i) PEC16M5 Trainer module.

ii) PEC16M2/M3 Trainer module.

iii) CRO.

iv) R - L Load.

FORMULA USED

Output voltage, V0 = DVS.

Where
D - Duty Cycle Ratio tan/T
ton - ON time.
T - Cycle Time [T = 1/f]

CIRCUIT DIAGRAM

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
CONNECTION PROCEDURE

1) Connect P1 of 24V DC to P2 of IGBT1

2) Connect P4 of IGBT1 to P7 of IGBT2

3) Connect P8 of 24V DC to P9 of IGBT2

4) Connect R - L load between P4 of IGBT1 and P6 of IGBT4

5) Connect pulse output through 9 pin connector of chopper control module to 9 pin
connector of IGBT/MOSFET power module using a 9 pin cable.

EXPERIMENTAL PROCEDURE

1) Switch ON the power ON/OFF switch in the MOSFET/IGBT power module LED
glows. Press reset switch to reset the trainer module. LED switches OFF.

2) Switch ON the 24V DC ON/OFF switch (SW1).

3) Switch ON power ON/OFF switch of PEC16M5 trainer module.

4) Select the four quadrant unipolar chopper operation mode by setting the switching
knob at position 3.

5) Switch ON pulse ON/OFF switch to release the pulse to the power module.

6) Observe the test waveforms in the test points provided on trainer module.

7) Adjust the duty cycle adjustment knob from minimum to maximum and note
down the output DC voltage.

8) Adjust switching frequency adjustment knob from minimum to maximum and

note down the output DC voltage.

NOTE

Protection circuit is provided in the power module. When Load current increases above 1.5A to
2A the protection circuit automatically resets the power circuit, thus protecting the devices.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Table :1

Switching frequency = Hz

S.No Ton D = ton/T Measured Vo Calculated

(S) (V) Vo(V)

Table :2

Ton = S

S.No Ton D = ton/T Measured Vo Calculated

(S) (V) Vo(V)

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
EXPERIMENT - 4

AIM

To study the Four quadrant chopper bipolar switching operation using PEC16M5 and
PEC16M2/M3 module.

EQUIPMENT REQUIRED

i) PEC16M5 Trainer module.

ii) PEC16M2/M3 Trainer module.

iii) CRO.

iv) R - L Load.

FORMULA USED

Output voltage, V0 = DVS.

Where
D - Duty Cycle Ratio tan/T
ton - ON time.
T - Cycle Time [T = 1/f]

CIRCUIT DIAGRAM

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
CONNECTION PROCEDURE

1) Connect P1 of 24V DC to P2 of IGBT1

2) Connect P4 of IGBT1 to P7 of IGBT2

3) Connect P8 of 24V DC to P9 of IGBT2

4) Connect R - L load between P4 of IGBT1 and P6 of IGBT4

5) Connect pulse output through 9 pin connector of chopper control module to 9 pin
connector of IGBT/MOSFET power module using a 9 pin cable.

EXPERIMENTAL PROCEDURE

1) Switch ON the power ON/OFF switch in the MOSFET/IGBT power module LED
glows. Press reset switch to reset the trainer module. LED switches OFF.

2) Switch ON the 24V DC ON/OFF switch (SW1).

3) Select the four quadrant bipolar chopper operation mode by setting the switching
knob at position 4.

4) Switch ON power ON/OFF switch of PEC16M5 trainer module.

5) Switch ON pulse ON/OFF switch to release the pulse to the power module.

6) Observe the test waveforms in the test points provided on trainer module.

7) Adjust the duty cycle adjustment knob from minimum to maximum and note
down the output DC voltage.

8) Adjust switching frequency adjustment knob from minimum to maximum and

note down the output DC voltage.

NOTE :

Protection circuit is provided in the power module. When Load current increases above 1.5A to
2A the protection circuit automatically resets the power circuit, thus protecting the devices.

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
Table :1

Switching frequency = Hz

S.No Ton D = ton/T Measured Vo Calculated

(S) (V) Vo(V)

Table :2

Ton = S

S.No Ton D = ton/T Measured Vo Calculated

(S) (V) Vo(V)

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APPENDIX
i. TL084 - Op. Amp

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ii. LM311N - Voltage Comparator

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iii. CD4098B - Monoshot

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iv. CD4081B - AND Gate

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IGBT/MOSFET CHOPPER CONTROL CIRCUIT PEC16M5
v. CD4011B - NAND Gate

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