IRPT3054A IRPT3054A PROVISIONAL ™ Power Module for 5 hp Motor Drives · 5 hp (3.7 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-baseplate isolation 2500V rms Easy-to-mount two-screw package Case temperature range -25°C to 125°C operational 380-480V 3-phase input IRPT3054A Power Module Figure 1. IRPT3054A Power Module PWM variable frequency output Gate Driver Board feedback (non-isolated) PWM generator Figure 2. The IRPT3054 power module within a motor control system page 1 IRPT3054A Power Module The IRPT3054A 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 3-phase 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 IGBTs and ultrafast freewheeling diodes. Current sensing is achieved through 25 m low inductance shunts provided in the positive and negative DC bus rail. The NTC thermistor provides page 2 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 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 mounted to a heat sink with two screw mount positions, in order to ensure good thermal contact between the module substrate and the heat sink. IRPT3054A Specifications PARAMETERS Input Power VALUES Voltage 380V, -15%, 480V +10%, 3-phase Frequency 50/60 Hz Current 11.8A rms @ nominal output IFSM 400A CONDITIONS TA = 40°C, RthSA = 0.51°C/W 10 ms half-cycle, non-repetitive surge Output Power Voltage 0 - 480V rms Nominal motor hp (kW) 5 hp (3.7 kW) nominal full load power Nominal motor current defined by external PWM control Vin = 440V AC, 150% overload for 1 minute fpwm = 4 kHz, f0 = 60 Hz, 8.4A nominal full load power TA = 40°C, RthSA = 0.51°C/W 12.6A 150% overload for 1 minute DC Link DC link voltage 850V maximum Brake Current 15.1A Sensor Temp. sense resistance Current sense Protection 50 kOhms ±5% @ TNTC = 25°C 3.1 kOhms ± 10% @ TNTC = 100°C 25mOhms ±5% @ TSHUNT = 25°C IGBT short circuit time 5 µs Recommended short circuit- 46A peak DC Bus = 850V, VGE = 15V, line to line short shutdown current Gate Drive QG 94 nC (typical) Recommended gate driver IR2233 (with buffer) @ VGE = 15V, refer figure 4b Module Isolation voltage 2500V rms Operating case temperature -25°C to 125°C Mounting torque 1 Nm Storage temperature range -40°C to 125°C Soldering temperature for 10 sec. 260°C maximum pin to baseplate, 60 Hz, 1 minute 95% RH max. (non-condensing) M4 screw type at the pins (.06" from case) page 3 IRPT3054A 0.8 350 5 hp (3.7kW) RthSA 100% load (continuous) 10-60 Hz 0.6 300 250 0.5 200 0.4 Power 150% 150 0.3 0.2 Power 100% 100 RthSA 150% load (1 min.)10-60 Hz 50 RthSA 150% load (1 min.) down to 3 Hz 0.1 0 0 1 4 8 12 16 20 24 PWM Frequency (kHz) – (Induction Motor Load) Figure 3. 5 hp/8.4A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency NOTE: For figure 3: Operating Conditions: Vin = 460 Vrms, MI = 1.15, P.F. = 0.8, TA = 40°C, Ti < 145°C, Ts < 95°C, Z thSA limits ∆Tc rise during 1 minute overload to 10°C page 4 Total Power Dissipation (Watt) Thermal Resistance(RthSA°C/W) 0.7 IRPT3054A Figure 4a. Typical Capacitance vs Collector-to-Emitter Voltage Figure 4b. Typical Gate Charge vs Gate-to-Emitter Voltage Figure 4c. Typical Transfer Characteristics Figure 5. Nominal R-T Characteristics of the NTC Thermistor page 5 IRPT3054A Mounting, Hookup and Application Instructions Mounting Power Connections 1. Connect the driver board and the IRPT3054A 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 and power module and into the heat sink and tighten the screws to 1 Nm torque. The power module pin designation, function and other details can be obtained from the package outline (figure 7) and circuit diagram (figure 8). 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. 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 1 2 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 Figure 6. Power Module Mounting Screw Sequence page 6 IRPT3054A IRPT3054A Mechanical Specifications NOTE: Dimensions are in inches (millimeters) 31X 3.215 .032 [0.81] .650 .020 [0.51] [16.51] N/C RT1 RT2 G5 E5 THICKNESS G3 E3 G1 E1 RP P IS1 IS2 N R [81.66] 2.105 2.040 [51.82] 1.662 W G4 E4 G6 E6 N/C V U G7 IS4 IS3 G2 E2 BR T [42.21] S [53.47] F HATCHED SURFACE 3.854 [97.89] .307 [7.80] .507 [12.87] HATCHED SURFACE E Figure 7a. page 7 IRPT3054A IRPT3054A Mechanical Specifications NOTE: Dimensions are in inches (millimeters) ALL PIN COORDINATE DIMENSIONS ARE BASIC 1.450 [36.83] 1.350 [34.29] 1.550 [39.37] .850 [21.59] .750 [19.05] .450 [11.43] .050 [ 1.27] .350 [ 8.89] .350 [ 8.89] .050 [ 1.27] .450 [11.43] .550 [13.97] .650 [16.51] 2X Ø .104 ± .002 [2.64 ± 0.05] 1.250 [31.75] 1.550 [39.37] 3.420 [86.87] MINUS DRAFT X .400 Ø .010 S 1.020 [25.91] A B-C PIN CENTER G .187 [4.75] .175 [4.45] 2X B C .800 [20.32] .000 [ 0.00] .400 [10.16] 2X R .250 [6.35] 4X Ø .260 [6.60] PIN CENTER 1.250 [31.75] 1.150 [29.21] .950 [24.13] 1.050 [26.67] .550 [13.97] .250 [ 6.35] .000 [ 0.00] .150 [ 3.81] .250 [ 6.35] .950 [24.13] 1.450 [36.83] 1.750 [44.45] 1.020 [25.91] PIN DIAGONAL .037 - .034 [.940 - .864] 31X Ø .019 M E-F Ø .010 M E-F G B-C 31X ( .026 - .024) 31X .050 [1.27] HATCHED SURFACE E F HATCHED SURFACE MOUNTING SURFACE IN CLAMPED CONDITION A Figure 7b. page 8 IRPT3054A RP P IS1 IS2 E1 G1 RS1 D7 D9 D11 E3 G3 Q1 D13 E5 G5 Q3 D1 RT1 Q5 D3 RT2 D5 RT Q7 R S T U V W Q2 D8 D10 D12 Q4 D2 Q6 D4 D6 RS2 N BR G7 IS4 1S3 G2 E2 G4 E4 G6 E6 Figure 8. Power Module Circuit Diagram page 9 IRPT3054A Functional Information Heat Sink Requirements Over-Temperature Protection Figure 3 shows the thermal resistance of the heat sink required for various output power levels and pulse-width-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. 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 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. IRPT3054A Part Number Identification and Ordering Instructions IRPT3054A 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. NTC temperature sensing thermistor and current sensing low-inductance shunts. page 11 IRPT3054A 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. 7/97 page 12