PD 60142 IRPT1066A PROVISIONAL ™ Power Module for 0.5 hp Motor Drives · 0.5 hp (0.37 kW) power output Industrial rating at 150% overload for 1 minute · · · · · · · · · 180-240V AC single-phase input, 50/60 Hz Single-phase rectifier bridge 3-phase, short circuit rated, ultrafast IGBT inverter HEXFRED ultrafast soft recovery freewheeling diodes 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 -25oC to 125oC operational Figure 1. IRPT1066A Power Module 180-240V single-phase input IRPT1066A Power Module Gate Driver Board PWM generator PWM variable frequency output AC motor feedback (non-isolated) feedback processing keyboard Figure 2. The IRPT1066A Power Module within a motor control system IRPT1066A The IRPT1066A Power Module The IRPT1066A 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 single-phase input bridge rectifiers are rated at 800V. The inverter section employs 600V, short circuit rated, ultrafast IGBTs and ultrafast freewheeling diodes. Current sensing is achieved through 150 mΩ low inductance shunts provided in the positive and negative DC bus rail. The NTC thermistor provides temperature sensing capability. The lead spacing on the power module meets UL840 pollution level 3 requirements. page 2 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 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. IRPT1066A Specifications PARAMETERS VALUES C O N D IT IO N S In p u t P o w e r Voltage F re q u e n c y 2 2 0 V A C , -1 5 % , + 1 0 % , s in g le -p h a s e 50/60 H z C u rre n t 6 .7 A r m s @ n o m in a l o u tp u t IFS M 150A T A = 4 0 o C , R th S A = 1 . 6 6 4 o C / W 1 0 m s h a lf-c y c le , n o n -r e p e titiv e s u r g e O u tp u t P o w e r Voltage 0 - 230V rms N o m in a l m o to r h p (k W ) 0 .5 h p (0 .3 7 k W ) n o m in a l fu ll lo a d p o w e r 1 5 0 % o v e r lo a d fo r 1 m in u te d e fin e d b y e x te r n a l P W M c o n tr o l N o m in a l m o to r c u rre n t 2 .9 A n o m in a l fu ll lo a d p o w e r 4 .3 5 A 1 5 0 % o v e r lo a d fo r 1 m in u te Vin = 220V, fpwm = 4 kHz, fo = 6 0 H z , T A = 4 0 o C , R th S A = 1 . 6 6 4 o C / W D C Lin k D C lin k v o lta g e 4 2 5 V m a x im u m S en sor Temp. sense resistance 5 0 kO hm s ± 5 % 3 .1 k O h m s ± 1 0 % @ T N TC = 2 5 oC @ T N TC = 1 0 0 oC C u rre n t se n se 150mO hms ±2% @ TSH U N T = 2 5 oC P ro te c tio n IG B T s h o r t c irc u it tim e 10 µs R e c o m m e n d e d s h o r t c irc u its h u td o w n c u rre n t 12A peak DC bus = 425V, VGE = 15V, line to line short G a te D riv e QG 1 9 n C (ty p ic a l) R e c o m m e n d e d g a te d riv e r IR 2 1 3 2 J (s e e F ig u re 9 ) @ VGE = 15V, refer Figure 4b M o d u le Is o la tio n v o lta g e 2500V rms o p in -to -b a s e p la te , 6 0 H z , 1 m in u te o O p e ra tin g c a s e te m p e ra tu re -2 5 C to 1 2 5 C M o u n tin g to rq u e 1 Nm o 9 5 % R H m a x . (n o n -c o n d e n s in g ) M 4 s c re w ty p e o S to ra g e te m p e ra tu re ra n g e -4 0 C to 1 2 5 C S o ld e r in g te m p e r a tu r e fo r 1 0 s e c . 2 6 0 oC m a x im u m a t th e p in s (.0 6 " fr o m c a s e ) page 3 IRPT1066A 70 RthSA 100% load (continuous) 10-60 Hz 60 0.5 hp (0.37 kW) 2 50 Power 150% 1 .5 40 30 RthSA 150% load (1 min.) 10-60 Hz 1 Power 100% Total Power Dissipation (Watts) Thermal Resistance (RthSAoC/W) 2 .5 20 0 .5 RthSA 150% load (1 min.) down to 3 Hz 10 0 0 1 4 8 12 16 20 24 PWM Frequency (kHz) – (induction Motor Load) Figure 3a. 0.5 hp/2.9A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency 3 Thermal Resistance (RthSAoC/W) 35 2.5 0.25 hp (0.185 kW) Power 150% 30 2 25 1.5 20 15 1 RthSA 150% load (1 min.) down to 3 Hz Power 100% 10 RthSA 150% load (1 min.) 10-60 Hz 0.5 Total Power Dissipation (Watts) 40 RthSA 100% load (continuous) 10-60 Hz 0 5 0 1 4 8 12 16 20 24 PWM Frequency (kHz) – (induction Motor Load) Figure 3b. 0.25 hp/1.9A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency NOTE: For Figures 3a and 3b: Operating Conditions: Vin = 230Vrms, MI = 1.15, PF = 0.8, TA = 40oC, ZthSA limits ∆Tc rise during 1 minute overload to 10oC page 4 IRPT1066A 400 20 V G E , G ate -to-Emitter Voltage (V) V GE 0V, 1MH z V f f== 1MHz GE ==0V, C ies = C + C , , CCcece SHORTED SHOR TED C ies = Cgege+ Cgcgc C res ==CC gc C res gc C oes==CC ce+ +CC gc C oes ce gc C , C a p acita nce (pF ) 300 C ies 200 100 C oes VVCC 400V CC == 400V IICC ==5.0A 5.0A 16 12 8 4 C res 0 0 1 10 100 0 4 8 12 16 20 Q G , Total Gate Charge (nC) V CE , Collector-to-Emitter Voltage (V) Figure 4a. Typical Capacitance vs Collector-to-Emitter Voltage Figure 4b. Typical Gate Charge vs Gate-to-Emitter Voltage I C , Collector-to-Emitter Current (A) 100 10 °C TTJJ =150 = 150oC TTJJ =25 = 25oC°C 1 5 10 V CC = 50V 5µs PULSE WIDTH 15 20 V GE , Gate-to-Emitter Voltage (V) Figure 4c. Typical Transfer Characteristics Figure 5. Nominal R-T Characteristics of the NTC Thermistor page 5 IRPT1066A Mounting Procedure Functional Information Mounting Heat Sink Requirements 1. Connect the driver board and the IRPT1066A power 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 flatners is .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. Figures 3a-3b 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-widthmodulation. These maximum 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 output frequency, IGBT junction temperature tends to follow the instantaneous fluctuations of the output current. Thus, peak junction temperature rise increases as output frequency decreases. 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 2 1 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 Figure 6. Power Module Mounting Screw Sequence Power Connections The power module pin designation, function and other details can be obtained from the package outline Figure 7 and circuit diagram Figure 8. Single-phase input connections are made to pins R and S and inverter output connections made to pins U, V and W. 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. page 6 Over-Temperature Protection Over-temperature can be detected using the NTC thermistor included in the power module for thermal sensing. Protection circuit that initiates a shutdown if the temperature of the IMS substrate exceeds a set level can be implemented. The nominal resistance vs. temperature characteristic of the thermistor is given in Figure 5. 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 line voltage. Deceleration of the motor must be controlled by appropriate PWM control to keep the DC bus voltage within the rated maximum value. IRPT1066A NOTE: Dimensions are in inches (millimeters) Figure 7a. Power Module Package Outline page 7 IRPT1066A NOTE: Dimensions are in inches (millimeters) Figure 7b. Power Module Package Outline page 8 IRPT1066A Figure 8. Power Module Circuit Diagram page 9 IRPT1066A Figure 9. Recommended Gate Drive Circuit page 10 IRPT1066A Part Number Identification and Ordering Instructions IRPT1066A Power Module Chip and wire epoxy encapsulated module with 800V rectifiers, 600V short-circuit rated, ultra-fast IGBT inverter with ultra-fast freewheeling diodes, temperature sensing NTC thermistor and current-sensing low-inductance shunts. page 11 IRPT1066A 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/ Data and specifications subject to change without notice. 5/98 page 12