IRMDG62-1-D2 D2PAK IGBT Motor Drive Reference Design Kit Description The reference design power board is designed to showcase IR D2PAK IRGS4610DPBF IGBT in a motor drive application. Product Summary IGBT inverter power stage for 3 phase motors FR4 based 1oz copper two-layer PCB 100-240V AC input range 400W motor power range (with heatsink) Single shunt configuration The 84 x 125 mm board has two layers with 2 oz (~35µm) copper each. IRGR4610DPBF Features Features → Low VCE(ON) and switching losses Square RBSOA and maximum junction temperature of 175°C Positive VCE(ON) temperature coefficient and tight distribution of parameters 5µs short circuit SOA Lead-free, RoHS compliant 1 www.irf.com Benefits High efficiency in a wide range of applications and switching frequencies Improved reliability due to rugged hard switching performance and high power capability Excellent current sharing in parallel operation Enables short circuit protection scheme Environmentally friendly © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Safety Precautions In addition to the precautions listed throughout this manual, please read and understand the following statements regarding hazards associated with development system. ATTENTION: The ground potential of the IRMDG62-1-D2 system is biased to a negative DC bus voltage potential. When measuring voltage waveform by oscilloscope, the scope ground needs to be isolated. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: IRMDG62-1-D2 system contains dc bus capacitors which take time to discharge after removal of the main supply. Before working on the drive system, wait at least three minutes and until the capacitors have discharged to safe voltage levels. Failure to do so may result in personal injury or death. Darkened display LEDs is not an indication that capacitors have discharged to safe voltage levels. ATTENTION: Only personnel familiar with the drive and associated machinery should plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage. ATTENTION: The surface temperatures of the drive may become hot, which may cause injury. ATTENTION: IRMDG62-1-D2 system contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference applicable ESD protection handbook and guideline. 2 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 ATTENTION: An incorrectly applied or installed drive can result in component damage or reduction in product life. Wiring or application errors such as under sizing the motor, supplying an incorrect or inadequate AC supply, or excessive ambient temperatures may result in system malfunction. ATTENTION: Remove and lock out power from the drive before you disconnect or reconnect wires or perform service. Wait three minutes after removing power to discharge the bus voltage. Do not attempt to service the drive until bus voltage has discharged to zero. Failure to do so may result in bodily injury or death. ATTENTION: Do not connect power factor correction capacitors to output terminals U, V, and W. Doing so may result in equipment damage or bodily injury. ATTENTION: Debris When Unpacking IRMDG62-1-D2 system is shipped with packing materials that need to be removed prior to installation. Failure to remove all debris and packing materials which are unnecessary for system installation may result in overheating or abnormal operating condition. 3 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Hardware Description A top view of the IRMDG62-1-D2 board is shown below. J8: Motor connector J9: DC Input Bus capacitor Inverter power stage Power Supply Gate driver circuit J1: Control Connector J7: Aux supply 4 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Connector definition pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 5 www.irf.com Controller connector pin out (20 pin) PWMUH GND PWMUL GND PWMVH 3.3V input PWMVL 3.3V input PWMWH IU+ PWMWL IU- (GND) GATEKILL DCB+ (after R divider) VTH IV+/NC IV-(GND) IW+/NC IW-(GND) NC © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Specifications Parameters Values Conditions Watts 400W Vin=200VAC, fPWM=10kHz, TA=25C, with heat-sink Current 1.35 Arms Maximum DC bus voltage 400V Current sensing device Single DC shunt Power device IRGS4610DPBF 15V 15V+/-5%, Max 20mA Used for gate drive power supply 3.3V 3.3V+/-5%, Max 50mA Available on J1 PCB Material FR4, Copper thickness = 2oz (70um) Dimension 84mm x 125mm System environment Ambient temperature 0 to 70C 95% RH max. (Non-condensing) Running the system 1. Connect the system as in Figure 1 2. Power on the Vdc power supply (<400Vdc) 3. Start the control signal generator Inverter output Cable (not included) Figure 1 - Connection of control signals to the D2PAK board 6 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Test condition example PWM: IRMC1183 control board. Carrier frequency: 10KHz Load: motor test bench Motor: GK6063-6AF31-WE(KE=63V/1000r/min, normal 1000rpm, Io=2A) Power Board: IRMDG62-1-D2 IGBT: IRGS4610DPBF Phase to phase voltage Phase current Figure 2 - Example of the inverter phase current and phase to phase voltage for sinusoidal motor The board can drive up to a 400W motor with the heatsink under the PCB bottom (see Figure 3). 7 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Figure 3 - Max PCB temperature vs Output power with heatsink Schematic FR - 4 PCB material, max temperature define at 105C for Safe Operating Area 8 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 9 www.irf.com © 2015 International Rectifier September 7, 2015 IRMDG62-1-D2 Data and Specifications are subject to change without notice IR WORLD HEADQUARTERS: 233 Kansas St., El Segundo, California 90245, USA Tel: (310) 252-7105 TAC Fax: (310) 252-7903 Visit us at www.irf.com for sales contact information 10 www.irf.com © 2015 International Rectifier September 7, 2015