IRF IRPT2059A

PD 6.106
IRPT2059A
IRPT2059A
PRELIMINARY
™
Power Module for 2 hp Motor Drives
· 2 hp (1.5 kW) power output
Industrial rating at 150% overload for 1 minute
·
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·
·
·
·
·
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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
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
Figure 1. IRPT2059A Power Module
IRPT2059C
180-240V
3-phase input
IRPT2059A
Power
Module
IRPT2059D
Driver-Plus
Board
PWM
generator
PWM
variable
frequency
output
AC
motor
feedback
(non-isolated)
feedback
processing
keyboard
Revised 6/97
Figure 2. The IRPT2059C
control system
within a motor
page 1
IRPT2059A
System Description
The IRPT2059A Power Module
The IRPT2059A 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 3-phase input bridge
rectifiers are rated at 800V. The inverter section uses 600V,
short circuit rated, ultrafast IGBTs 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.
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.
and Design Kit
The IRPT2059C
(Figure 3) provides the
complete power conversion function for a 2 hp (1.5 kW) variable
voltage, variable frequency AC motor controller. The
combines the Power Module (IRPT2059A)
with a Driver-Plus Board (IRPT2059D). The
Design Kit, IRPT2059E includes the following:
• Complete
integrated power stage
• Specification and operating instructions
• Bill of materials
• Electrical schematic
• Mechanical layout for Driver-Plus Board
• Software transferrable file for easy design integration
• Application information and layout considerations
Figure 3. IRPT2059C
page 2
IRPT2059A
Specifications
PARAMETERS
Input Power
VALUES
Voltage
220V, -15%, +10%, 3-phase
Frequency
50/60 Hz
Current
11.2A rms @ nominal output
IFSM
300A
CONDITIONS
TA = 40°C, RthSA = 0.72°C/W
10 ms half-cycle, non-repetitive surge
Output Power
Voltage
0 - 230V rms
Nominal motor hp (kW)
2 hp (1.5 kW) nominal full load power
defined by external PWM control
Vin = 220V AC, fpwm = 4 kHz,
Nominal motor current
150% overload for 1 minute
8A rms nominal full load power
12A rms 150% overload for 1 minute
fo = 60 Hz,
TA = 40°C, RthSA = 0.72°C/W
DC Link
DC link voltage
425V maximum
Brake
Current
14.4A
Sensor
Temp. sense resistance
Current sense
50kOhms ±5%
@ TNTC = 25°C
3.1kOhms ±10%
@ TNTC = 100°C
45mOhms ±5%
@ TSHUNT = 25°C
Protection
IGBT short circuit time
Recommended short circuitshutdown current
10 µs
36A peak
DC bus = 425V, VGE = 15V, line to line short
Gate Drive
QG
67 nC (typical)
Recommended gate driver
IR2133J (refer Figure 10)
V GE = 15V, refer Figure 5b
refer to design kit IRPT2059E
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
IRPT2059A
1
160
RthSA 100% load
(continuous)10-60 Hz
140
0.8
120
0.7
100
0.6
0.5
Power
150%
80
RthSA 150% load
(1 min.)10-60 Hz
0.4
Power
100%
0.3
RthSA 150% load (1 min.)
down to 3 Hz
2.0 hp
(1.5 kW)
0.2
60
Total Power Dissipation (Watts)
Thermal Resistance (RthSA°C/W)
0.9
40
20
0.1
0
0
1
4
8
12
16
20
24
PWM Frequency (kHz) – (Induction Motor Load)
Figure 4a. 2 hp/8A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency
2.5
80
70
RthSA 100% load
2
continuous 10-60 Hz
60
50
1.5
Power
150%
40
1
RthSA 150% load
Power
100%
(1 min.) 10-60 Hz
30
RthSA 150% load (1 min.)
down to 3 Hz
Total Power Dissipation (Watts)
Thermal Resistance (RthSA°C/W)
1 hp
(0.75 kW)
20
0.5
10
0
0
1
4
8
12
16
20
PWM Frequency (kHz) – (Induction Motor Load)
24
Figure 4b. 1 hp/4.4A 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 ∆T c rise
during 1 minute overload to 10°C
page 4
IRPT2059A
VGE = 0V, f = 1MHz
C ies = C ge + C gc , C ce SHORTED
C res = C gc
C oes = C ce+ Cgc
1200
C ies
900
600
C oes
300
C res
0
1
10
100
VCE , Collector-to-Emitter Voltage (V)
Figure 5a. Typical Capacitance vs
Collector-to-Emitter Voltage
20
VGE, Gate-to-Emitter Voltage (V)
C, Capacitance (pF)
1500
VCC = 400V
I C = 16A
16
12
8
4
0
0
20
40
60
80
QG, Total Gate Charge (nC)
Figure 5b. Typical Gate Charge vs
Gate-to-Emitter Voltage
IC , Collector-to-Emitter Current (A)
100
T J = 150 o C
10
o
1
T J = 25 C
VCC = 50V
5µs PULSE WIDTH
0.1
5
10
15
VGE, Gate-to-Emitter Voltage (V)
Figure 5c. Typical Transfer Characteristics
Figure 6. Nominal R-T Characteristics of the
NTC␣ Thermistor
page 5
IRPT2059A
Mounting Procedure
Functional Information
Mounting
Heat Sink Requirements
1. Connect the driver board and the IRPT2059A 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.
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2
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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 in Figure 8 and circuit
diagram in Figure 9. Three phase input connections made to pins
R, S and T and inverter output connections are 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 DC 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.
IRPT2059A
IRPT2059A 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 8a. Package Outline and Mechanical Specifications
page 7
IRPT2059A
IRPT2059A Mechanical Specifications
NOTE: Dimensions are in inches (millimeters)
ALL PIN COORDINATE DIMENSIONS ARE BASIC
1.350 [34.29]
1.450 [36.83]
1.550 [39.37]
.850 [21.59]
.450 [11.43]
.750 [19.05]
.350 [ 8.89]
.050 [ 1.27]
.050 [ 1.27]
.450 [11.43]
.350 [ 8.89]
.650 [16.51]
.550 [13.97]
1.550 [39.37]
2X Ø .104
± .002
[2.64 ± 0.05]
1.250 [31.75]
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
1.150 [29.21]
PIN DIAGONAL
.037 - .034
1.250 [31.75]
.950 [24.13]
1.050 [26.67]
.550 [13.97]
.250 [ 6.35]
.000 [ 0.00]
.250 [ 6.35]
.150 [ 3.81]
.950 [24.13]
1.450 [36.83]
1.750 [44.45]
1.020 [25.91]
[.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 8b. Package Outline and Mechanical Specifications
page 8
IRPT2059A
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 9. Power Module Circuit Diagram
page 9
IRPT2059A
Figure 10. Recommended Gate Drive Circuit
page 10
IRPT2059A
Part Number Identification and Ordering Instructions
IRPT2059A Power Module
IRPT2059D 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.
IRPT2059C
Integrated Power Module (IRPT2059A) and Driver-Plus
Board (IRPT2059D) pre-assembled and tested to meet all system
specifications.
IRPT2059E Design Kit
Complete
(IRPT2059C) with full set of
design documentation including schematic diagram, bill of
material, mechanical layout of Driver-Plus Board, schematic
files, Gerber files and design tips.
page 11
IRPT2059A
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/
Dataandspecificationssubjecttochangewithoutnotice.
6/97
page 12