IRPT2056A

PD 6.099 IRPT2056A PRELIMINARY IRPT2056A ™ Power Module for 3 hp Motor Drives · 3 hp (2.2 kW) power output Industrial rating at 150% overload for 1 minute · · · · · · · · · · 180-240V AC input, 50/60 Hz 3-phase rectifier bridge 3-phase, short circuit rated, ultrafast IGBT inverter HEXFRED ultrafast soft recovery-freewheeling diodes Brake IGBT and diode Low inductance (current sense) shunts in positive and negative DC rail NTC temperature sensor Pin-to-baseplate isolation 2500V rms Easy-to-mount two-screw package Case temperature range -25°C to 125°C operational Figure 1. IRPT2056A Power Module IRPT2056C IRPT 2056A Power Module IRPT 2056D Driver-Plus Board PWM variable frequency output 180-240V 3-phase input feedback (non-isolated) PWM generator Figure 2. The power module and motor control system within a page 1 IRPT2056A System Description Power Module The IRPT2056A Power Module, shown in figure 1, is a chip and wire epoxy encapsulated module. It houses input rectifiers, output inverter, current sense shunts and NTC thermistor. The 3phase input bridge rectifiers are rated at 800V. The brake circuit uses 600V IGBT and freewheeling diode. The inverter section employs 600V, short circuit rated, ultrafast IGBT's and ultrafast freewheeling diodes. Current sensing is achieved through 25 mΩ low inductance shunts provided in the positive and negative DC bus rail. The NTC thermistors provide temperature sensing capability. The lead spacing on the power module meets UL840 pollution level 3 requirements. The power circuit and layout within the module are carefully designed to minimize inductance in the power path, to reduce noise during inverter operation and to improve the inverter efficiency. The Driver-Plus Board required to run the inverter can be soldered to the power module pins, thus minimizing assembly and alignment. The power module is designed to be mounted to a heat sink with two screw mount positions, in order to insure good thermal contact between the module substrate and the heat sink. and Design Kit The IRPT2056C (Figure 3) provides the complete power conversion function for a 3 hp (2.2 kW) variable voltage, variable frequency AC motor controller. The combines the Power Module (IRPT2056A) with a Driver-Plus Board (IRPT2056D). The Design Kit, IRPT2056E includes the following: • Complete integrated power stage • Specification and operating instructions • Bill of materials • Electrical schematic • Mechanical layout of the Driver-Plus Board • Software transferrable file for easy design integration • Application information and layout considerations Figure 3. IRPT2056C page 2 IRPT2056A Specifications PARAMETERS Input Power Voltage Frequency Current IFSM VALUES 220V AC, -15%, +10%, 3-phase 50/60 Hz 15.4A rms @ nominal output 400A 0-230V rms 3 hp (2.2 kW) nominal full load power 150% overload for 1 minute 11A nominal full load power 16.5A 150% overload for 1 minute 400V maximum 20A 50 kOhms ± 5% 3.1kOhms ± 10% 25mOhms ± 5% 10 µs 70A peak CONDITIONS TA = 40°C, RthSA = 0.42°C/W 10ms half-cycle, non-repetitive surge defined by external PWM control V in = 230V AC, fpwm = 4kHz, fo = 60 Hz, TA = 40°C, RthSA = 0.42°C/W Output Power Voltage Nominal motor hp (kW) Nominal motor current DC Link DC link voltage Brake Current Sensor Temp. sense resistance Current sense @ TNTC = 25°C @ TNTC = 100°C @ TSHUNT = 25°C DC bus = 400V, VGE = 15V, line to line short Recommended short circuitshutdown current Protection IGBT short circuit time Gate Drive QG 120 nC (typical) @ VGE = 15V, refer figure 5b Recommended gate driver IR2133 (see Figure 10) 2500V rms -25°C to 125°C 1 Nm -40°C to 125°C at the pins (.06" from case) pin-to-baseplate, 60 Hz, 1 minute 95% RH max. (non-condensing) M4 screw type Module Isolation voltage Operating case temperature Mounting torque Storage temperature range Soldering temperature for 10 sec. 260°C maximum page 3 IRPT2056A 0.6 Thermal Resistance (R thSA°C/W) 300 RthSA 100% Load Continuous 10-60 Hz Power 150% 3 hp (2.2 kW) 200 0.4 0.3 Power 100% 0.2 RthSA 150% Load (1 min.) Down to 3 Hz 0.1 RthSA 150% Load 1 min.)10-60 Hz 150 100 50 0 1 4 8 12 16 20 24 0 PWM Frequency (kHz) – (Induction Motor Load) Figure 4a. 3hp/11A output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency 0.9 0.8 Thermal Resistance (R thSA°C/W) RthSA 100% Load Continuous 10-60 Hz 2 hp (1.5 kW) 200 180 160 140 120 Total Power Dissipation (Watts) 0.7 0.6 0.5 Power 150% 100 0.4 0.3 0.2 0.1 0 Power 100% 80 RthSA 150% Load (1 min.) Down to 3 Hz RthSA 150% Load (1 min.) 10-60 Hz 60 40 20 0 1 4 8 12 16 20 24 PWM Frequency (kHz) – (Induction Motor Load) Figure 4b. 2hp/8A output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency NOTE: For Figures 4a and 4b: Operating Conditions: V in = 230V rms, MI =1.15, PF = 0.8, TA = 40 °C, Tj < 145°C, Ts < 95°C, ZthSA limits ∆ Tc during 1 minute overload to 10°C page 4 Total Power Dissipation (Watts) 0.5 250 IRPT2056A 3000 2500 20 C, Capacitance (pF) = 0V, V GE C ies = C ge + C res = C gc Coes= C ce + f = 1MHz Cgc , C ce SHORTED Cgc 2000 C ies 1500 1000 500 0 VGE , Gate-to-Emitter Voltage (V) VCC = 400V IC = 25A 16 12 8 C oes C res 1 10 100 4 0 0 20 40 60 80 100 120 140 VCE , Collector-to-Emitter Voltage ( Figure 5a. Typical Capacitance vs Collector-to-Emitter Voltage Q , Total Gate Charge (nC) G Figure 5b. Typical Gate Charge vs Gate-to-Emitter Voltage 100 I C , Collector-to-Emitter Current (A) TJ = 150°C TJ = 25°C 10 V CC = 50V 5µ s PULSE WIDTH•A 1 5 7 9 11 V , Gate-to-Emitter Voltage (V) GE Figure 5c. Typical Transfer Characteristics Figure 6. Nominal R-T Characteristics of the NTC Thermistor page 5 IRPT2056A Mounting, Hookup and Application Instructions Mounting 1. Connect the driver board and the IRPT2056A module. 2. Remove all particles and grit from the heat sink and power substrate. 3. Spread a .004" to .005" layer of silicone grease on the heat sink, covering the entire area that the power substrate will occupy. Recommended heat sink flatness in .001 inch/inch and Total Indicator Readout (TIR) of .003 inch below substrate. 4. Place the power substrate onto the heat sink with the mounting holes aligned and press it firmly into the silicone grease. 5. Place the 2 M4 mounting screws through the PCB and power module and into the heat sink and tighten the screws to 1 Nm torque. Power Connections The power module pin designation, function and other details can be obtained from the package outline (figure 8) and circuit diagram (figure 9). 3-phase input connections are made to pins R, S and T and inverter output connections are made to pins U, V and W. Positive DC bus and brake IGBT collector connections are brought out to pins P and BR, respectively. Positive rectifier output and positive inverter bus are brought out to pins RP and P, respectively, in order to provide DC bus capacitor soft charging implementation option. The current shunt terminals are connected to pins IS1, IS2 and IS3, IS4 on the positive and negative DC rails, respectively. Figure 7. Power Module Mounting Screw Sequence page 6 098765432109876543210987654321 09876543210987654321098765432 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 098765432109876543210987654321 1 098765432109876543210987654321 1 2 IRPT2056A IRPT2056A Mechanical Specifications NOTE: Dimensions are in inches (millimeters) 3.854 [97.89] 3.215 [81.66] 31X HATCHED SURFACE .032 [0.81] .020 [0.51] THICKNESS RT1 RT2 N/C G3 E3 G5 E5 F .650 [16.51] R N 2.105 [53.47] 1.662 [42.21] RP P IS1 IS2 G1 E1 2.040 [51.82] BR G7 IS4 IS3 G2 E2 G4 E4 G6 E6 N/C U S T V W .307 [7.80] .507 [12.87] HATCHED SURFACE E Figure 8a. Package Outline and Mechanical Specifications page 7 IRPT2056A IRPT2056A Mechanical Specifications NOTE: Dimensions are in inches (millimeters) ALL PIN COORDINATE DIMENSIONS ARE BASIC 3.420 [86.87] 1.350 [34.29] 1.250 [31.75] 1.450 [36.83] 1.550 [39.37] 2X Ø .104 ± .002 [2.64 ± 0.05] MINUS DRAFT X .400 Ø .010 G S A B-C 1.550 [39.37] .650 [16.51] .550 [13.97] .450 [11.43] .450 [11.43] .750 [19.05] .050 [ 1.27] .350 [ 8.89] .850 [21.59] .350 [ 8.89] .050 [ 1.27] 1.020 [25.91] PIN CENTER 2X C .800 [20.32] .400 [10.16] .187 [4.75] .175 [4.45] B .000 [ 0.00] 2X R .250 [6.35] 4X Ø .260 [6.60] PIN CENTER 1.020 [25.91] PIN DIAGONAL .037 - .034 [.940 - .864] 31X Ø .019 Ø .010 31X ( .026 - .024) 31X .050 [1.27] M M E-F E-F G B-C 1.750 [44.45] 1.450 [36.83] 1.050 [26.67] 1.150 [29.21] 1.250 [31.75] .950 [24.13] .550 [13.97] .950 [24.13] .250 [ 6.35] .150 [ 3.81] .000 [ 0.00] .250 [ 6.35] HATCHED SURFACE F E HATCHED SURFACE MOUNTING SURFACE IN CLAMPED CONDITION A Figure 8b. Package Outline and Mechanical Specifications page 8 IRPT2056A RP P IS1 IS2 E1 G1 E3 G3 E5 G5 RT1 RT2 RS1 D7 D9 D11 D13 Q1 D1 Q3 D3 Q5 D5 RT R S T Q7 U V W Q2 D2 Q4 D4 Q6 D6 D8 D10 D12 RS2 N BR G7 IS4 1S3 G2 E2 G4 E4 G6 E6 Figure 9. Power Module Circuit Diagram Figure 10. Recommended Gate Drive Circuit page 9 IRPT2056A Functional Information Heat Sink Requirements Figures 4a through 4b show the thermal resistance of the heat sink required for various output power levels and pulse-widthmodulated (PWM) switching frequencies. Maximum total losses of the unit are also shown. This data is based on the following key operating conditions: • The maximum continuous combined losses of the rectifier and inverter occur at full pulse-width-modulation. These losses set the maximum continuous operating temperature of the heat sink. • The maximum combined losses of the rectifier and inverter at full pulse-width modulation under overload set the incremental temperature rise of the heat sink during overload. • The minimum output frequency at which full load current is to be delivered sets the peak IGBT junction temperature. • At low frequency, IGBT junction temperature tends to follow the instantaneous fluctuations of the output current. Thus, peak junction temperature rise increases as output frequency decreases. Over-Temperature Protection Over-temperature can be detected using the NTC thermistor included in the power module for thermal sensing. A protection circuit that initiates a shutdown if the temperature of the IMS exceeds a set level can be implemented. The nominal resistance vs. temperature characteristic of the thermistor is given in figure 6. Voltage Rise During Braking The motor will feed energy back to the DC link during regenerative braking, forcing the bus voltage to rise above the level defined by the input voltage. Deceleration of the motor must be controlled by appropriate PWM control to keep the DC bus voltage within the rated maximum value. For high inertial loads, or for very fast deceleration rates, this can be achieved by connecting an external braking resistor across P and BR and controlling the brake IGBT switching when the bus voltage exceeds the allowable limit. page 10 IRPT2056A Part Number Identification and Ordering Instructions IRPT2056A Power Module Chip and wire epoxy encapsulated module with 800V input rectifiers, 600V brake IGBT and freewheeling diode, 600V short-circuit rated, ultra-fast IGBT inverter with ultra-fast freewheeling diodes, NTC temperature sensing thermistor and current sensing low-inductance shunts. IRPT2056D Driver-Plus Board Printed circuit board assembled with DC link capacitors. NTC in-rush limiting thermistors, high-power terminal blocks, surge suppression MOVs, IGBT gate drivers, protection circuitry and low power supply. The PCB is functionally tested with standard power module to meet all system specifications. IRPT2056C Complete IRPT2056A Power Module and IRPT2056D Driver-Plus Board pre-assembled and tested to meet all system specifications. IRPT2056E Design Kit Complete (IRPT2056C) with full set of design documentation including detailed schematic diagram, bill of material, mechanical layout, schematic file, Gerber files and design tips. page 11 IRPT2056A WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, Tel: (310) 322 3331 EUROPEAN HEADQUARTERS: Hurst Green, Oxted, Surrey RH8 9BB, UK Tel: ++ 44 1883 732020 IR CANADA: 7321 Victoria Park Ave., Suite 201, Markham, Ontario L3R 2Z8, Tel: (905) 475 1897 IR GERMANY: Saalburgstrasse 157, 61350 Bad Homburg Tel: ++ 49 6172 96590 IR ITALY: Via Liguria 49, 10071 Borgaro, Torino Tel: ++ 39 11 451 0111 IR FAR EAST:171 (K&H Bldg.), 3-30-4 Nishi-ikebukuro 3-Chome, Toshima-ku, Tokyo Japan Tel: 81 3 3983 0086 IR SOUTHEAST ASIA: 315 Outram Road, #10-02 Tan Boon Liat Building, Singapore 0316 Tel: 65 221 8371 http://www.irf.com/ Dataandspecificationssubjecttochangewithoutnotice. 5/97 page 12