AgileStack Spec Sheet

AgileStack Spec Sheet
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Key Data
Configuration: 3 Phase Inverter Configuration
Rated output: 100kW
General Information
Standard configuration includes: (3) IGBT Modules, (3) Gate Drive Boards, (3) Current Sensors, (1) Interface Board, (1) Heat Sink
Topology
Application / Modulation
3 Phase Inverter (B6I)/ Single Phase Inverter
Inverter / Sine or Custom
Load Type
Standards
Resistive, Inductive
Designed to UL508C
Cooling
Markets
Current Sensors
IGBT Modules
Gate Drive Boards
Interface Board
Forced Air
Solar, Wind, UPS, Storage, Motor Control, Mining,
Traction, Induction, Frequency Conversion
Open Loop Hall Effect Sensor
IXYS – SimBus F MIXA450PF1200TSF XPT
AgileSwitch – EDEM2S
AgileSwitch – INEX2
Heat Sink
High Performance Extruded
Key Features
The AgileStack is the industry’s first, and only, patented fully software configurable power conversion module that
features SwitchStream™ technology to control, protect, and monitor 40 points of operating and fault conditions
and Stack BlackBox™ technology to store on-board fault data in the event of a catastrophic failure.
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TM
The AgileStack Serial SwitchStream system is a true digital protocol that allows differential bi-directional streaming of real
time operational and failure data about how the overall system is performing, eliminating the need to isolate signals and
develop complex code to control and interpret A/D converters.
SwitchStream™ technology enables 40 unique points of fault controls, monitoring and reporting, including:
 For each IGBT Half Bridge (“HB”), both HI/LO, 18 faults including: DSAT, UVLO, Gate Acknowledge
 For each IGBT HB, 12 faults including: Cross Latch/Shoot Thru, DC Link Overvoltage, Overcurrent, Over temperature
 For the Stack, 9 points of monitoring (3 points for each HB) including: DC Link Voltage, Current, Temperature
Stack BlackBox™ technology stores operating and fault conditions in the event of Stack failure, even if the system is no
longer powered, allowing for robust failure analysis and diagnosis.
The modular design of the Stack, based on globally trusted, best-in-class component manufacturers of IGBTs, gate drives,
current sensors, bus bars and cooling solutions, enables short lead times and multi-sourcing of components as well as full
stack serviceability.
Complete Stack configurability enables precision control of the IGBTs to optimize performance, efficiency, lifetime, and
EMI/EMC with component/software modifications to: soft turn off, gate resistors, dead time, DSAT timing, cross latch/shoot
through timing and controlled or automatic reset.
Differential or single ended 3V trigger inputs enables high signal integrity over long cable connections to the controller.
Separate connectors for Triggers/Signals and Power reduce system noise and errors.
Switching frequencies up to 20 KHz standard. (Up to 30 KHz with lower current IGBTs/water cooled systems).
Manual Reset by the host.
Factory calibration parameters and settings available on request by the Controller. Can be field modified.
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
Page 1 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Topology Overview
The AgileStack is comprised of the following main electronic/electrical core components: (3) IXYS SimBus F IGBT modules
(1200V/450A), (3) AgileSwitch Gate Drive Boards, (1) AgileSwitch Interface Board and (3) Current Sensors.
The AgileSwitch Interface Board connects externally to both a host controller and power supply. The Gate Drive Boards and
Current Sensors each connect internally to the Interface Board. The Gate Drive Boards are soldered directly to each of the IXYS
SimBus F IGBT Modules.
Trigger and Reset Signals from the Control Board are transmitted through the Interface Board to the IGBTs. The Gate Drive
Boards transmit real time temperature for each IGBT Module (HB) and high voltage data to the Interface Board, along with
acknowledgement of gate triggering and specific fault conditions. The Gate Drive Boards also control the nature and timing of
turn on/turn off of the IGBTs, as well as shut down in the event of certain fault conditions. The Current Sensors transmit real
time current data to the Interface Board.
These signals are isolated on the Interface Board, where calculations are performed to convert all data into a digital format. This
TM
data is then transmitted to the Controller in digital form using the AgileStack SwitchStream serial communication protocol.
This high speed process allows for unprecedented control, protection, and monitoring of the electronics in the Power Stack. It
further simplifies controller development and programming, as all isolation and DA conversion protocols are established. It is
truly a “plug and play” system that enables rapid product development, testing and deployment.
The modular approach further allows for easily configurable (often software controlled) modifications to performance
characteristics of the Stack, as well as for simplified debugging, repair, failure analysis, and second sourcing of key components.
3 Phase (B6I) Shown
*DC link capacitors and Controller Optional
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
Page 2 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Note: Operating Conditions:
3
VDC=680, VAC=480, FSW=5kHz, cos (ϕ) = .9, airflow = 485 m /hr, air temp = 25°C, IAC=150 ARMS
Electrical Characteristics
DC Data
DC link Voltage
Max Surge Voltage
Overvoltage Shutdown
Notes
Continuous Operation
2 min, non-operational
Configurable
Symbol
VDC
-
min
280
880
typ
900
max
900
1200
920
unit
V
V
V
AC Data
Voltage
Continuous Current
Power Loss
Switching Frequency
Notes
Symbol
VAC
IAC
Ploss
FSW
min
-
typ
100
1800
5
max
635
150
20
unit
Vrms
Arms
W
kHz
Cos(ϕ)
-
0
-
-
1
900
Arms
Symbol
-
min
typ
3.5
max
unit
kV
Symbol
ΔV/ΔtAir
ΔPAir
Tinlet
min
-25
typ
485
410
25
max
50
unit
3
m /hr
Pa
°C
Symbol
TStor
TAmb
min
-40
-25
typ
-
max
85
50
unit
°C
°C
Alt
Pair
Rel. F
MAC
900
5
280
280
16
70
13
7.6
215
215
-
90
1000
1100
85
162
80
20
°C
m
hPa
%
kg
kg
mm
mm
Nm
Power Factor
Surge Current
General Data
Insulation Test Voltage
Per phase. See Typical Operating Conditions
See Typical Operating Conditions
See Typical Operating Conditions. Max
frequency is @ 50°C. (Up to 30kHz with
lower current IGBTs/water cooled systems)
Leading or Lagging
Max for 10 µs
Notes
Heat Sink Air Cooled/Thermal Data
Data
Airflow
Air Pressure Drop
Cooling Air Inlet Temperature
Notes
See Typical Operating Conditions
Typical Operating Conditions are supported
over this operating range, including Tmax.
Environmental Conditions
Data
Storage Temp
Ambient Temp
Heat Sink Temperature
Altitude above sea level
Air Pressure
Humidity
Total Weight
Weight w/o Heat Sink
Dimensions
Heat Sink Dimensions
Torque at AC terminals
AgileStack 100KW Spec Sheet V05 (IXYS)
Notes
Non-operational
Continuous Operation
Note: different from Tinlet
Derated operation possible above Alt Max
Standard Atmosphere
Non-condensing
LxWxH
LxWxH
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Page 3 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
IGBT Module Data – IXYS SimBus F MIXA450PF1200TSF XPT (Spec sheet - http://ixapps.ixys.com/DataSheet/MIXA450PF1200TSF.pdf)
Module Absolute Maximum Ratings
Collector-Emitter Voltage
Gate-Emitter Voltage
Collector Current
Collector Power Dissipation
Junction Temperature
Isolation Voltage
Notes
TJ = 25ºC
Symbol
Vces
Vges
Ic
Pc
Tj
Viso
min
-40
-
typ
-
max
1200
±20
450
2100
150
3000
unit
V
V
A
W
°C
VAC
IGBT Data
Collector-Emitter Saturation voltage
Collector-Emitter Saturation voltage
Thermal resistance junction to case
Thermal resistance case to heat sink
Temperature Sensor NTC
Temperature Sensor NTC
Notes
Ic=450A, Vge=15V, Tj = 25°C
Ic=450A, Vge=15V, Tj = 125°C
min
-
typ
1.8
2.15
0.03
5
3375
max
2.15
Resistance, Tj = 25°C
Temperature coefficient
Symbol
Vce_sat
Vce_sat
Rthjc
Rthch
R25
B25/50
unit
V
V
K/W
K/W
kΩ
K
Diode Data
Thermal resistance junction to case
Thermal resistance case to heat sink
Notes
For one device
For one device
Symbol
Rthjc
Rthch
typ
0.04
max
0.095
Continuous
1 Device
Maximum / Operating
Terminals to baseplate, 1 min
Collector Current vs. Collector-Emitter Voltage (typ.)
VGE=15 V, TJ=25ºC/125ºC
Collector Current vs. Collector-Emitter voltage (typ.)
TJ=125ºC
Forward Current vs. Forward Voltage (typ.)
AgileStack 100KW Spec Sheet V05 (IXYS)
4.75
min
-
.06
5.25
unit
K/W
K/W
Turn-on Energy vs. Gate Resistor
Typ. NTC Resistance vs. Temperature
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Page 4 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
External Input/Output Data
Input - DC Link Bus Connections
There are 6 DC Link Bus Connections. These connections are positive and negative connections to the 3 HB sections in the AgileStack.
Item
Description/Value
Bus Connections (+)
Positive high voltage bus connections to HI Side collector of each HB
Bus Connections (-)
Negative high voltage bus connections to LO Side emitters of each HB
Nominal Current Capacity
150A (RMS)
Mounting Holes
M6x1 – 16 mm
Copper Bus Bars
18.0x2.0 mm
Tin Plating Thickness
0.05 mm
Output - Connections 1, 2, 3 (for HB1, HB2, HB3)
There are three output connectors. These connectors are located at the center point output of each HB.
Item
Description/Value
Bus Connections 1, 2, 3
High Voltage DC Output
Nominal Current Capacity
150A (RMS)
Mounting Holes
M8x1.2 – 25 mm
Copper Bus Bars
15.8x2.0 mm
Tin Plating Thickness
0.05 mm
Interface Connectors
Controller to Interface Board – J1
Power to Interface Board – J2
Programmer to Interface Board – J3
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
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AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Controller Interface Overview
Data
Power Voltage Input
Power Input
Driver Board
Input Signal Logic HI Level
Input Signal Logic LO Level
Digital Output Level
DC Voltage Measurement Range
Current Measurement Range
Temperature Measurement Range
Notes
Vin = 12V, 15V, or 24V
1k input impedance
Open collector, low=ok, max sink: 10mA
Actual measurements transmitted digitally
over serial communications lines.
Symbol
min
typ
max
unit
Vin
18
24
28
V
Paux
30
W
EDEM2S (EconoDual Electrical Master 2S)
Vin_hi
2.7
3.0
3.5
V
Vin_lo
-0.5
0.4
0.7
V
Vout
0
3.3
V
Vdc_range
50
1000
V
Iac_range
-900
+900
A
T range
-40
150
°C
Power to Interface Board (J2) Connector Data
Pin No
1
3
Signal
VCC
GND
Pin No
2
4
Signal
GND
VCC
Controller to Interface Board (J1) Connector Data
Pin No
1
3
5
7
9
11
13
15
17
19
21
23
25
Signal
BOT-HB1-TRIG (+)
GND
TOP-HB1-TRIG (+)
BOT-HB2-TRIG (+)
GND
TOP-HB2-TRIG (+)
BOT-HB3-TRIG (+)
GND
TOP-HB3-TRIG (+)
RESET
Tx (+)
FAULT
Rx (+)
Pin No
2
4
6
8
10
12
14
16
18
20
22
24
26
Signal
BOT-HB1-TRIG (-)
TOP-HB1-TRIG (-)
GND
BOT-HB2-TRIG (-)
TOP-HB2-TRIG (-)
GND
BOT-HB3-TRIG (-)
TOP-HB3-TRIG (-)
GND
GND
Tx (-)
GND
Rx (-)
Controller to Interface Board (J1) Connection Overview
There are six trigger signals that control the switching information to the IGBTs. A reset line allows the host to reset the Stack
upon power up and after fault conditions. A single fault line is used to indicate that a fault has occurred. Detailed information
about the fault is transmitted over the serial interface.
The 26-Pin connector (J1) offers differential trigger signals on all signals except RESET and FAULT. The Trigger signals can be used
singled ended, with positive or negative logic, by grounding the unused signals. For example if the system noise allows, the TRIG
(-) signals can be grounded and only the Trig (+) signal used.
Trigger Lines (1, 2, 4, 5, 7, 8, 10, 11, 13, 14, 16, 17):
6 IGBT control signals - BOT and TOP for each HB.
Reset Line (19):
Host controlled reset on power up and post fault. This signal is an active high, meaning the reset is indicated by a high signal.
Fault Line (23):
This signal indicates that a fault has occurred. It is an active high (goes high to indicate fault) output signal and is an open
collector requiring a pull up resistor and capacitor (470Ω and 1000nF) for noise immunity. The actual fault condition can be
interrogated via the serial communication path. It should be considered as an IRQ or NMI in a standard microprocessor system
with a 3.3V pull up level.
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
Page 6 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Serial Interface Lines (21, 22, 25, 26):
Faults are transmitted and values are monitored over a full duplex differential serial interface which transmits at up to a 10 MHz
data rate.
1. Current Sensing: Three 14-bit current sensors; a 16-bit signed value for each phase is triggered via the SYNC command
or Trigger input.
2. Temperature Sensing: Three 12-bit temperature sensors; a 16-bit signed value for each HB @1 KHz Sample Rate.
3. DC Link Voltage: Three 12-bit DC Link Voltage sensors; a 16-bit signed value for the 3 DC-Link Voltage levels.
4. Fault Conditions (only transmitted in the event of a fault on request by the Controller):
Global status fault information transmitted in every packet sent from the AgileStack. Detailed HB info can be requested
by Host controller.
5. Calibration Parameters
Factory calibration parameters and settings are available on request by the Controller. Can be field modified.
TM
AgileStack SwitchStream Bi-directional Serial Communication System allows:
• The timing for when the A/D current sampling occurs can be configured for each HB. The timing can be triggered from
the SYNC command or a trigger input with a programmable delay.
• Temperature and DC-Link Voltage measurements can be sent from the SYNC command or on request.
• Actions to be taken automatically upon a fault.
• Factory or in-field calibration of current, voltage and temperature sensors.
Basic Serial Interface Protocol
• Current measurements are transmitted automatically via the SYNC command or trigger input.
• Temperature and DC-Link Voltage for all three HBs are transmitted automatically via the SYNC command or by Host
register read request.
Fault Management
A Global status byte is sent with every Current, DC Link Voltage, and Temperature packet. The Global status byte includes the
following data:
1. Global Fault Status
2. Global Over Temperature Fault Status
3. Global Over Current Fault Status
4. Global Over Voltage Fault Status
5. Global DSAT Fault Status
6. Global Under Voltage Fault Status
7. HB[1:0] at Fault
Fault Recording – Stack BlackBox™ (Future Firmware Release)
The AgileStack continually stores the state of the system in a buffer. In the event of a fault:
– The last 8 states are stored in EEPROM.
– Each time a fault occurs the data is stored. Up to 1,000 fault occurrences can be stored.
– This takes 5 ms to store and occurs even with loss of power.
– This information can be retrieved for future failure analysis.
Programmer to Interface Board (J3) Connector Data
–
The programmer connector is a 10 pin, 2 row, 0.1cc connector that is used to update the AgileStack firmware with
additional features. This connector can only be used with the proper update software and programmer supplied by
AgileSwitch. Please review the AgileStack User Manual for more information.
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
Page 7 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Control/Protection/Faults/Monitors
Fault Table
Fault Condition/Action
Desat - HI
Desat – LO
UVLO – HI
UVLO - LO
Cross Latch/Shoot Through
DC Link Overvoltage
Overcurrent
Over Temperature
*Configurable parameters
Generic Sample Default Trigger Values
>7 Volts for 6.1 µs*
>7 Volts for 6.1 µs*
<12 Volts
<12 Volts
Attempt to turn on both IGBTs
simultaneously
900 Volts*
500 A*
>125C*
Action on IGBT if Active
Turn off HI side
Turn off LO side
Turn off HI side
Turn off LO side
Does not allow turn on of inactive
IGBT until active is off for 2 µs*
Shut down all IGBTs*
Shut down all IGBTs*
Shut down all IGBTs*
Connector Hardware
J1 Connector Hardware
Connector
Ribbon Cable
Interface Board
Type
26 Pins
26 Pins
Manufacturer Part Number
TE Connectivity 1658622-6
TE Connectivity 5499923-6
J2 Connector Hardware
Connector
Wire Cable
Interface Board
Type
4 Pins
4 Pins
Manufacturer Part Number
TE Connectivity 640599-4
TE Connectivity 640445-4
J3 Connector Hardware
Connector
Wire Cable
Interface Board
Type
10 pins
10 pins
Manufacturer Part Number
Supplied by AgileSwitch
Supplied by AgileSwitch
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
Page 8 of 10
AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Mechanical Dimensions
Dimensions are in mm. To view the full drawing, please visit www.AgileSwitch.com/download.page.
Additional Materials
The purpose of this spec sheet is to provide a fundamental understanding of the AgileStack. To learn more, we recommend
reviewing the AgileStack User Manual and AgileStack Quick Start Guide. The user manual has includes a comprehensive
description of technical details that a user will need to know to begin configuring the AgileStack to their application. After
reviewing the user manual, consult the Quick Start Guide to learn about power up options and setting up basic parameters
including current, voltage, and temperature.
AgileStack User Manual
AgileStack Quick Start Guide
Revisions
Prepared By
A. Fender
Approved By
R. Weber
AgileStack 100KW Spec Sheet V05 (IXYS)
Version
05 (IXYS)
Date
3/11/2015
Description
See Rev 3 release notes, also changed IGBT specs for IXYS part
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
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AgileStack Spec Sheet
PRELIMINARY
100 kW DC-AC/ DC-DC Inverter
Legal Disclaimer
Information in this document is provided solely in connection with AGILESWITCH products. AGILESWITCH, LLC and its subsidiaries
(“AGILESWITCH”) reserve the right to make changes, corrections, modifications or improvements, to this document, and the products and
services described herein at any time, without notice.
All AGILESWITCH products are sold pursuant to AGILESWITCH’s terms and conditions of sale.
Purchasers are solely responsible for the choice, selection and use of AGILESWITCH products and services described herein, and AGILESWITCH
assumes no liability whatsoever relating to the choice, selection or use of the AGILESWITCH products and services described herein.
No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. If any part of this
document refers to any third party products or services it shall not be deemed a license grant by AGILESWITCH for the use of such third party
products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of
such third party products or services or any intellectual property contained therein.
UNLESS OTHERWISE SET FORTH IN AGILESWITCH’S TERMS AND CONDITIONS OF SALE AGILESWITCH DISCLAIMS ANY EXPRESS OR IMPLIED
WARRANTY WITH RESPECT TO THE USE AND/OR SALE OF AGILESWITCH PRODUCTS INCLUDING WITHOUT LIMITATION IMPLIED WARRANTIES
OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE (AND THEIR EQUIVALENTS UNDER THE LAWS OF ANY JURISDICTION), OR
INFRINGEMENT OF ANY PATENT, COPYRIGHT OR OTHER INTELLECTUAL PROPERTY RIGHT.
UNLESS EXPRESSLY APPROVED IN WRITING BY AN AUTHORIZED AGILESWITCH REPRESENTATIVE, AGILESWITCH PRODUCTS ARE NOT
RECOMMENDED, AUTHORIZED OR WARRANTED FOR USE IN MILITARY, AIR CRAFT, SPACE, LIFE SAVING, OR LIFE SUSTAINING APPLICATIONS,
NOR IN PRODUCTS OR SYSTEMS WHERE FAILURE OR MALFUNCTION MAY RESULT IN PERSONAL INJURY, DEATH, OR SEVERE PROPERTY OR
ENVIRONMENTAL DAMAGE.
AGILESWITCH PRODUCTS WHICH ARE NOT SPECIFIED AS "AUTOMOTIVE GRADE" MAY ONLY BE USED IN AUTOMOTIVE APPLICATIONS AT
USER’S OWN RISK.
Resale of AGILESWITCH products with provisions different from the statements and/or technical features set forth in this document shall
immediately void any warranty granted by AGILESWITCH for the AGILESWITCH product or service described herein and shall not create or
extend in any manner whatsoever, any liability of AGILESWITCH.
AGILESWITCH, the AGILESWITCH logo, AgileStack, AgileStack Communications and Stack Black Box are trademarks or registered trademarks of
AGILESWITCH, LLC in various countries. Any other names are the property of their respective owners.
Information in this document supersedes and replaces all information previously supplied.
Specifications are subject to change without notice.
© 2010-2015 AGILESWITCH LLC - All rights reserved www.AgileSwitch.com.
Patent Notices
Offering
TM
AgileStack Power Stack
Issued U.S. Patent Numbers
8,984,197
Manufacturer
AgileSwitch, LLC
1650 Arch Street, #1905
Philadelphia, PA 19103
United States
Tel:
+1-484-483-3256 (US)
+44 (0)1273 252994 (Europe)
+86 (10) 60539835 (China)
Email: info@AgileSwitch.com
Web: www.AgileSwitch.com
AgileStack 100KW Spec Sheet V05 (IXYS)
CONFIDENTIAL AND PROPRIETARY TO AGILESWITCH, LLC
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