I'm building an H-Bridge power stage switch to drive and RLC circuit which features an induction coil and capacitor tank coupled by an 10:1 toroidal transformer to the H-bridge output, working in the frequency interval of [60,90] KHz. To maintain the RLC locked on its resonance frequency I used an PPL that reads the frequency of the coil and locks on it.
I'm trying to use the ADuM7234 to drive the MOSFETS or IGBTs at 80V maximum and maximum current that can reach 120A, limited by the power source. I don't believe that so much current will be needed because I already built an H-Bridge based on the Linear LT1162 IC that when working drained 20A at 40V.
I intend to use this induction heater to heat 25um thick, 1cm2 copper foils until 1050ºC as fast as I can inside a reactor with controlled atmosphere.
So the problems and questions:
- The output of the PLL (CD4046) and the input in the BNC plug are a 12Vpp square wave, so I put the TLP2955 and TLP2958 opto-couplers to reference the signal to 5V and invert it also. Do you have other component suggestion that make the same result but with less delay and low noise sensitivity?
- The output of the opto-couplers (Vopp) decreases when I plug them to the ViA and ViB and I believe that it is an impedance mismatch since when I remove the 1K resistance (R3 and R4) the signal gets better. So, what is the input impedance of the ADuM7234 and does it varies when on and off?
- I'm still testing the assembly in the breadboard so I understand that elevated parasitic impedances can be present but the chips overheat too fast, can this be from a problem in the circuit topology?
- I'm using a computer power source to get the 5V and 12V that have a common ground, should I use two separated power sources to have isolated grounds? Should I use separated power sources, one for each ADuM7234?
- The Disable pin needs to be grounded for the drivers to work?
- The gate resistors are 3.3Ohm and not 1K, can I put just a ferrite instead of the gate resistor to reduce the initial turn on ripple?
- The LT1162 IC used a resistor between the upper MOSFETs gate and source, but from the Analog application note ( Inside iCoupler Technology: Driving an H Bridge with ADuM3220 Isolated Gate Drivers) it's not included, is there a reason for this, or should I include one close the loop during in the charging cycle of the bootstrap capacitors?
- When I increase the power (VPP), the gate signal gets distorted, what can be the reason for this?
- Is the ADuM7234 prepare to handle big gate capacitances?
I hope it was clear in my questions
It sounds like you are using the optocoupler as a level shifting inverter. Since the ADuM7234 itself is an isolator, I don't know if isolation is needed at the location you are using the opto-couplers. Could you use a standard inverter instead, and use a resistor divider to reduce the 12 V square wave to something around 5V? Or, could you do an open drain output with an N-FET with a 5 V supply?
The ADuM7234 has CMOS inputs, and when it is powered up, should look like a high-impedance. When the ADuM7234 is not powered up, putting voltage on the input pins may parasitically power the ADuM7234 through internal protection diodes, so it is no recommended to feed the input pins when the unit is unpowered on VDD1.
If the chips are overheating, there might be a problem somewhere else. I don't think the parasitic inductances should add that much power dissipation to the system.
Each highside output of the ADuM7234 needs it's own power source. This could be as simple as a bootstrap capacitor if the circuit meets duty cycle and frequency requirements. The circuit note on the ADuM7234 uses a special configuration because the bus voltage is low. In your case, with a bus voltage of 80 V, we need to find a way to power the high sides independently of the bus voltage. Here is an app note about that subject:
Yes, the Disable pin needs to be grounded. If left floating, it can float high, thereby shutting the output off.
The external series gate resistor not only serves to dampen the turn on and turn off edges, but also serves to help spread the power dissipation of the gate drive outside of the gate driver. 3.3 Ω is a suitable external series gate resistor size. A ferrite bead can sometimes help, but it is still recommended to have an external series resistor in place.
The resistors from gate to source sometimes found in gate driver schematics serves to help the system be at a known state when the gate driver is unpowered, or damaged. They are not always needed, but are a good idea most of the time. The values usually are in the 1kΩ-100kΩ range, where they won't affect the quiescent current drastically, but should something go wrong, or the gate driver become unpowered, the MOSFET gate will be discharged to the source voltage through this resistor.
Do you have a waveform capture of this?
The power dissipated within the gate driver is directly proportional to the gate charge of the device being driven, as well as the switching frequency the system is running at. The ADuM7234 should definitely be able to run the power device you mention, with a 120 A target current. This all depends on the max ambient temperature the system will be running at as well.