PD 60120 IRPT2061A PRELIMINARY ™ Power Module for 1.5 hp Motor Drives · 1.5 hp (1.1 kW) power output Industrial rating at 150% overload for 1 minute · · · · · · · · · · 380-480V 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-base plate isolation 2500V rms Easy-to-mount package Case temperature range -25oC to 125oC operational Figure 1. IRPT2061A Power Module 380-480V 3-phase input IRPT2061A Power Assembly Gate Driver Board PWM generator PWM variable frequency/ voltage isolated feedback feedback processing keyboard External Control Functions Figure 2. The IRPT2061A power module within a motor control system AC motor IRPT2061A The IRPT2061A Power Module The IRPT2061A power module shown in Figure 1 is a chip and wire epoxy encapsulated module. It houses input rectifiers, brake IGBT and freewheeling diode, output inverter, current sense shunts and NTC thermistor. The 3phase input bridge rectifiers are rated at 1600V. The brake circuit uses 1200V IGBT and freewheeling diode. The inverter section employs 1200V, short circuit rated ultrafast IGBT's and ultrafast freewheeling diodes. Current sensing is achieved through 45 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 a heat sink with two screw mount positions, in order to insure good thermal contact between the module substrate and the heat sink. IRPT2061A 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 3 8 0 V A C , -1 5 % , 4 8 0 V + 1 0 % , 3 -p h a s e 50/60 H z C u rre n t 4 .4 A r m s @ n o m in a l o u tp u t IFS M 400A T A = 4 0 o C , R th S A = 1 . 4 0 6 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 - 480V rms N o m in a l m o to r h p (k W ) 1 .5 h p ( 1 . 1 k W ) n o m i n 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 N o m in a l m o to r c u rre n t 3 .1 A r m s n o m in a l fu ll lo a d p o w e r 4 .6 5 A 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 V in = 4 6 0 V A C , fp w m = 4 k H z , fo = 6 0 H z , T A = 4 0 o C , R th S A = 1 . 4 0 6 o C / W D C Lin k D C lin k v o lta g e 8 5 0 V m a x im u m B ra k e C u rre n t 5 .6 A 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 @ TN TC = 1 0 0 oC C u rre n t se n se 45mO hms ±4% @ 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 14A peak DC bus = 850V, VGE = 15V, line to line short G a te D riv e QG 5 3 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 2 3 3 ( r e fe r F ig u r e 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 e ra tin g c a s e te m p e ra tu re -2 5 o C to 1 2 5 o C M o u n tin g to rq u e 1 Nm S to ra g e te m p e ra tu re ra n g e -4 0 o C to 1 2 5 o 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 p in -to -b a s e p la te , 6 0 H z , 1 m in u te 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 a t th e p in s (.0 6 " fr o m c a s e ) page 3 RthSA 100% load (continuous) 10-60 Hz Power 150% 1.5 hp (1.1 kW) Power 100% Power 150% RthSA 150% load (1 min.) down to 3 Hz Total Power Dissipation (Watts) Thermal Resistance (RthSAoC/W) IRPT2061A RthSA 150% load (1 min.) 10-60 Hz RthSA 100% load (continuous) 10-60 Hz 1hp (0.74 kW) Power 100% Power 150% RthSA 150% load (1 min.) 10-60 Hz Total Power Dissipation (Watts) Thermal Resistance (RthSAoC/W) Figure 3a. 1.5hp/3.1A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency (Induction Motor Load) RthSA 150% load (1 min.) down to 3Hz Figure 3b. 1hp/2.2A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency (Induction Motor Load) NOTE: For Figures 3a and 3b: Operating Conditions: Vin = 460Vrms, MI = 1.15, PF-0.8, TA = 40oC, Ti = 145oC, TS = 95oC, ZthSA limits ∆Tc during 1 minute overload to 10oC page 4 IRPT2061A Figure 4a. Typical Capacitance vs Collector-to-Emitter Voltage of the IGBT Figure 4b. Typical Gate Charge vs Gate-to-Emitter Voltage of the IGBT TJ = 150oC TJ = 25oC Figure 4c. Typical Transfer Characteristics of the IGBT Figure 5. Nominal R-T Characteristics of the NTC Thermistor (YNE503J01TR) page 5 IRPT2061A Mounting Procedure Mounting Power Connections 1. Connect the driver board and the IRPT 2061A 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 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. Insert the two M4 mounting screws through the PCB, power substrate and into the heat sink and tighten the screws to 1 Nm torque, according to the sequence shown in Figure 6. The power module pin designation, function and other details can be obtained from the package outline in Figure 7 and circuit diagram in Figure 8. Three 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 BP and P respectively in order to provide DC bus capacitor to pins IS1, IS2 and IS3, IS4 on the positive and negative DC rails, respectively. 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 2 123456789012345678901234567890 1 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 Figure 6. Power Module Mounting Screw Sequence page 6 IRPT2061A NOTE: Dimensions are in inches (millimeters) Figure 7a. Power Module Package Outline page 7 IRPT2061A Figure 7b. Power Module Package Outline page 8 IRPT2061A Figure 8. Power Module Circuit Diagram Figure 9. Recommended Gate Drive Circuit page 9 IRPT2061A Functional Information Heat Sink Requirements Over Temperature Protection Figures 3a through 3b show the thermal resistance of the heat sink required for various output power levels and pulsewidth-modulated (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 increment 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 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. page 10 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. IRPT2061A Part Number Identification and Ordering Instructions IRPT2061A Power Module Chip and wire epoxy encapsulated module with 1600V input rectifiers, 1200V brake IGBT and freewheeling diode, 1200V short-circuit rated, ultrafast IGBT inverter with ultrafast freewheeling diodes, temperature sensing NTC thermistor and current sensor low inductance shunts. page 11 IRPT2061A 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