PD 6.112 IRPT1057A IRPT1057A PRELIMINARY ™ Power Module for 0.75 hp Motor Drives · 0.75 hp (0.56kW) 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 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. IRPT1057A Power Module IRPT1057C 180-240V 3-phase input IRPT1057A Power Module IRPT1057D Driver-Plus Board PWM generator PWM variable frequency output feedback (non-isolated) feedback processing keyboard Figure 2. The power module and motor control system within a page 1 IRPT1057A System Description The IRPT1057A Power Module The IRPT1057A 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 800V. The inverter section employs 600V, short circuit rated, ultrafast IGBTs and ultrafast freewheeling diodes. Current sensing is achieved through 75 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. 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. The IRPT1057C (Figure 3) provides the complete power conversion function for a 0.75 hp (0.56 kW) variable voltage, variable frequency AC motor controller. The combines the Power Module (IRPT1057A) with a Driver-Plus Board (IRPT1057D). Figure 3. IRPT1057C page 2 IRPT1057A Specifications PARAMETERS Input Power VALUES Voltage 220V AC, -15%, +10%, 3-phase Frequency 50/60 Hz Current 4.6A rms @ nominal output IFSM 150A CONDITIONS TA = 40°C, RthSA = 1.79°C/W 10ms half-cycle, non-repetitive surge Output Power Voltage 0 - 230V rms Nominal motor hp (kW) 0.75 hp (0.56 kW) nominal full load power Nominal motor current 150% overload for 1 minute 3.3A nominal full load power 4.95A 150% overload for 1 minute defined by external PWM control V in = 220V, fpwm = 4 kHz, fo = 60 Hz, TA = 40°C, RthSA = 1.79°C/W DC Link DC link voltage 425V maximum Sensor Temp. sense resistance Current sense 50 kOhms ± 5% @ TNTC = 25°C 3.1kOhms ± 10% @ TNTC = 100°C 75mOhms ±5% @ TSHUNT = 25°C Protection IGBT short circuit time Recommended short circuit- 10µs 18A peak DC bus = 425V, VGE = 15V, line to line short shutdown current Gate Drive QG 34 nC (typical) Recommended gate driver IR2132J (see Figure 10) @ VGE = 15V, refer Figure 5b 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 IRPT1057A 2.5 60 0.75 hp (0.56 kW) 2 50 40 1.5 Power 150% 30 RthSA 150% load (1 min.) 10-60 Hz 1 Total Power Dissipation (Watts) Thermal Resistance (RthSA°C/W) RthSA 100% Load (continuous) 10-60 Hz 20 Power 100% RthSA 150% Load (1 min.) Down to 3 Hz 0.5 10 0 0 1 4 8 12 16 20 24 PWM Frequency (kHz) – (Induction Motor Load) Figure 4a. 0.75 hp/3.3A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency 3.5 45 40 3 0.5 hp (0.37 kW) 35 2.5 30 2 25 Power 100% Power 150% RthSA 150% load (1 min.) 10-60 Hz 1.5 20 RthSA 150% load (1 min.) down to 3 Hz 1 0.5 15 Total Power Dissipation (Watts) Thermal Resistance (RthSA°C/W) RthSA 100% Load (continuous) 10-60 Hz 10 5 0 0 1 4 8 12 16 20 24 PWM Frequency (kHz) – (Induction Motor Load) Figure 4b. 0.5hp/2.2A output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency NOTE: For Figures 4a and 4b: Operating Conditions: Vin = 230Vrms, MI = 1.15, PF = 0.8, TA = 40°C, ZthSA limits ∆Tc rise during 1 minute overload to 10°C page 4 IRPT1057A Figure 5a. Typical Capacitance vs Collector-to-Emitter Voltage Figure 5b. Typical Gate Charge vs Gate-to-Emitter Voltage Figure 5c. Typical Transfer Characteristics Figure 6. Nominal R-T Characteristics of the NTC Thermistor page 5 IRPT1057A Mounting Procedure Functional Information Mounting Heat Sink Requirements 1. Connect the driver board and the IRPT1057A 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 4a-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 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 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 1 2 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 Figure 7. Power Module Mounting Screw Sequence 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. Three phase input connections are made to pins R, S and T 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 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 line voltage. Deceleration of the motor must be controlled by appropriate PWM control to keep the DC bus voltage within the rated maximum value. IRPT1057A IRPT1057A Mechanical Specifications NOTE: Dimensions are in inches (millimeters) Figure 8a. Package Outline and Mechanical Specifications page 7 IRPT1057A IRPT1057A Mechanical Specifications ALL PIN COORDINATE DIMENSIONS ARE BASIC .950 [24.13] .750 [19.05] [3.81] [6.35] [11.43] [13.97] .150 [3.81] .050 [1.27] E1 G1 .150 .250 .450 .550 .550 [13.97] .450 [11.43] .750 [19.05] RP P IS1 IS2 1.050 [26.67] NOTE: Dimensions are in inches (millimeters) E5 G5 E3 G3 N PIN CENTER RT1 RT2 N/C .875 [22.27] W E4 G4 E6 G6 N/C V U IS4 IS3 E2 G2 TT PIN CENTER S R .000 [0.00] PIN DIAGONAL 1.050 [26.67] .850 [21.59] .650 [16.51] .050 [1.27] .000 [0.00] .250 [6.35] .350 [8.89] .650 [16.51] .850 [21.59] .875 .[22.27] .037 – .034 [.940 – .864] 28X .010 M A 28X [ .026 – .024)] 28X .040 [1.02] MOUNTING SURFACE IN CLAMPED CONDITION –A– Figure 8b. Package Outline and Mechanical Specifications page 8 IRPT1057A Figure 9. Power Module Circuit Diagram page 9 IRPT1057A Figure 10. Recommended Gate Drive Circuit page 10 IRPT1057A Part Number Identification and Ordering Instructions IRPT1057A Power Module IRPT1057D Driver-Plus Board 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. 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. IRPT1057C Integrated Power Module (IRPT1057A) and Driver-Plus Board (IRPT1057D) pre-assembled and tested to meet all system specifications. page 11