IGBTs exploding

Orcino · 27th July 2009, 03:03 AM

Hi everbody.
In the sch attached in tests with variac with 110 vac works great, but in 230vac , i gradually increased the load, then in + or - 1.4 Kw the IGBTs explode.
Does anyone have any idea of what is happening ?

Thanks

Orcino/Brazil

star882 · 27th July 2009, 03:56 AM

Unlike MOSFETs, IGBTs cannot be paralleled unless they're very well matched. Split the PFC stage into 2 phases and run then 180 degrees out of phase.

You probably also need a capacitor in series with the transformers to prevent core saturation or modify it for current mode operation.

Eva · 27th July 2009, 08:33 AM

Which IGBTs explode? Is the current limiting of the PFC working properly?

IRGP4064 *can* be paralleled, it's designed for that.

darkfenriz · 27th July 2009, 12:39 PM

You haven't shown PFC controller. What type is that? Note that PFC current sense is negative related to primary ground.
Also, what's the purpose of implementing current mode control with a controller?

darkfenriz · 27th July 2009, 12:47 PM

Holy cr@p!
I've just noticed you try to make a poly-phase rectification of all 3 phases and then try to make a PFC with a single boost regulator

How do you imagine to correct the power factor of all 3 phases together if they are diode-ORed or commonly multi rectified (don't know the exact name for this technique) ??

Orcino · 27th July 2009, 01:51 PM

Hi, Not yet assembled the PFC, only the part of the full bridge and feed back de current.

The IGBTs exploding are the bridge, someone sees something wrong in the circuit f ?

darkfenriz · 27th July 2009, 02:06 PM

With this type of output filter you will experience high peaks in primary current, probably not reflected into secondary DC current sense. So the current sense is useless here.
Correct it into proper LC filter.
We still cannot see the control algorithm, as it is implemeted in DSP.
And maybe even more vital: why don't you sense the primary current?
Sensing secondary current the way you did it is asking for problems IMO, I do not really see how a proper current ramp could be created this way...

luka · 27th July 2009, 02:12 PM

WTF? am I wrong here, or I see that he has 3 phases and trying to rectify them with 2 single phase rectifiers?

darkfenriz · 27th July 2009, 02:16 PM

Quote:

WTF? am I wrong here, or I see that he has 3 phases and trying to rectify them with 2 single phase rectifiers?

That actually creates a 'proper' 3 phase rectifier, but I don't see how this could be PFCable

luka · 27th July 2009, 02:23 PM

nor do I, and PF in 3 -phase should be pretty good to start with, I mean no need for one in few kw range

What I would do, is make 3 PFCs, each for its own phase

27th July 2009, 03:56 AM	#2
star882 diyAudio Member Join Date: Mar 2007	Unlike MOSFETs, IGBTs cannot be paralleled unless they're very well matched. Split the PFC stage into 2 phases and run then 180 degrees out of phase. You probably also need a capacitor in series with the transformers to prevent core saturation or modify it for current mode operation. __________________ "Fully on MOSFET = closed switch, Fully off MOSFET = open switch, Half on MOSFET = poor imitation of Tiffany Yep." - also applies to IGBTs!

27th July 2009, 08:33 AM	#3
Eva diyAudio Member Join Date: Oct 2003 Location: Near the sea	Which IGBTs explode? Is the current limiting of the PFC working properly? IRGP4064 can be paralleled, it's designed for that. __________________ I use to feel like the small child in The Emperor's New Clothes tale

27th July 2009, 02:12 PM	#8
luka diyAudio Member Join Date: Sep 2005 Location: in Slovenia :)	WTF? am I wrong here, or I see that he has 3 phases and trying to rectify them with 2 single phase rectifiers? __________________ home page @ http://www.classdaudio.co.cc @ 24/7 all year long I FEEL SLOVENIA

27th July 2009, 02:23 PM	#10
luka diyAudio Member Join Date: Sep 2005 Location: in Slovenia :)	nor do I, and PF in 3 -phase should be pretty good to start with, I mean no need for one in few kw range What I would do, is make 3 PFCs, each for its own phase __________________ home page @ http://www.classdaudio.co.cc @ 24/7 all year long I FEEL SLOVENIA

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27th July 2009, 12:39 PM	#4
darkfenriz diyAudio Member Join Date: Jun 2004 Location: Warsaw	You haven't shown PFC controller. What type is that? Note that PFC current sense is negative related to primary ground. Also, what's the purpose of implementing current mode control with a controller?

27th July 2009, 12:47 PM	#5
darkfenriz diyAudio Member Join Date: Jun 2004 Location: Warsaw	Holy cr@p! I've just noticed you try to make a poly-phase rectification of all 3 phases and then try to make a PFC with a single boost regulator How do you imagine to correct the power factor of all 3 phases together if they are diode-ORed or commonly multi rectified (don't know the exact name for this technique) ??

27th July 2009, 01:51 PM	#6
Orcino diyAudio Member Join Date: Jul 2009	Hi, Not yet assembled the PFC, only the part of the full bridge and feed back de current. The IGBTs exploding are the bridge, someone sees something wrong in the circuit f ?

27th July 2009, 02:06 PM	#7
darkfenriz diyAudio Member Join Date: Jun 2004 Location: Warsaw	With this type of output filter you will experience high peaks in primary current, probably not reflected into secondary DC current sense. So the current sense is useless here. Correct it into proper LC filter. We still cannot see the control algorithm, as it is implemeted in DSP. And maybe even more vital: why don't you sense the primary current? Sensing secondary current the way you did it is asking for problems IMO, I do not really see how a proper current ramp could be created this way...

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