PD 6.092 IRPT1053A PRELIMINARY POWIRTRAIN Power Module for 1 hp Motor Drives · 1 hp (0.75kW) power output Industrial rating at 150% overload for 1 minute · 180 - 240V AC input, 50/60Hz · 3-phase rectifier bridge · 3-phase 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-base plate isolation 2500V rms · Easy-to-mount two-screw package · Case temperature range -25°C to 125°C operational Figure 1. IRPT1053A Power Module 180-240V 3-phase input IRPT1053A Power Module PWM variable frequency output IRPT1053D POWIRTRAIN Driver-Plus Board PWM generator AC motor feedback (non-isolated) feedback processing keyboard External Control Functions Figure 2. The IRPT1053C POWIRTRAIN within a motor control system Revised 3/97 Untitled-1 www.irf.com 1 page 1 10/17/97, 2:34 PM IRPT1053A The IRPT1053A Power Module PowIRtrain and Design Kit The IRPT1053A 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 3phase 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 45mΩ 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 IRPT1053A PowIRtrain (Figure 3) provides the complete power conversion function for a 1hp (0.75kW) variable voltage, variable frequency AC motor controller. The PowIRtrain combines the Power Module (IRPT1053A) with a Driver-Plus Board (IRPT1053D). The PowIRtrain Design Kit, IRPT1053E includes the following: • • • • • • • Complete PowIRtrain integrated power stage Specification and operating instructions Bill of materials Electrical schematic Mechanical layout for Driver-Plus Board Software transferrable files for easy design integration Application information and layout considerations Figure 3. IRPT1053C PowIRtrain page 2 Untitled-1 www.irf.com 2 10/17/97, 2:34 PM IRPT1053A Specifications PARAMETERS Input Power VALUES Voltage Frequency Current IFSM 220V, -15%, +10%, 3-phase 50 - 60Hz 6.2 Arms @ nominal output 175 A CONDITIONS TA = 40°C, RthSA = 1.07°C/W 10ms half-cycle, non-repetitive surge Output Power Voltage Nominal motor hp (kW) 0 - 230V rms 1hp (0.75kW) nominal full load power 150% overload for 1 minute 4.4A nominal full load current 6.6A 150% overload for 1 minute Nominal motor current defined by external PWM control Vin = 220V, fpwm = 4kHz, fo = 60Hz TA = 40°C, RthSA = 1.07°C/W DC Link DC link voltage 425V maximum Sensor Temp. sense resistance 50kOhms ± 5% 3.1kOhms ±10% @ TNTC = 25°C @ TNTC = 100°C Current sense 45mOhms ± 5% @ TSHUNT = 25°C Protection IGBT short circuit time Recommended short circuitshutdown current 10µs DC bus = 425V, VGE = 15V, line to line short 30A peak Gate Drive QG Recommended gate driver 39 nC (typical) IR2132J (see figure 10) VGE = 15V refer Figure 5b refer design kit IRPT1053E Module Isolation voltage 2500V rms Operating case temperature -25°C to 125°C Mounting torque 1 Nm Storage temp. range -40°C to 125°C Soldering temperature for 10 sec. 260°C maximum pin to base plate, 60Hz, 1 minute 95%RH max. (non-condensing) M4 screw type at the pins (.06" from case) www.irf.com Untitled-1 page 3 3 10/17/97, 2:34 PM IRPT1053A Thermal Resistance (RthSA°C/ W) 90 1.2 RthSA 100% load continuous 10-60 Hz RthSA 150% load (1 min) 10-60 Hz 1 0.8 80 70 Power 150% 60 50 0.6 0.4 40 Power 100% 1.0hp (0.75kW) 30 RthSA 150% load (1 min) down to 3 Hz Total Power Dissipation (Watts) 100 1.4 20 0.2 10 0 0 1 4 8 12 16 PWM Frequency (kHz) - (Induction Motor Load) 20 24 Figure 4a. 1hp/4.4A output Heat sink Thermal Resistance and Power Dissipation vs. PWM Frequency 70 Thermal Resistance (RthSA°C/ W) 1.6 RthSA 100% load continuous 10-60 Hz 1.4 60 50 1.2 Power 150% 40 RthSA 150% load (1 min) 10-60 Hz 30 1 RthSA 150% load (1 min) down to 3 Hz Power 100% 20 0.75hp (0.55kW) 0.8 Total Power Dissipation (Watts) 80 1.8 10 0.6 0 1 4 8 12 16 PWM Frequency (kHz) - (Induction Motor Load) 20 24 Figure 4b. 0.75hp/3.5A output Heat sink Thermal Resistance and Power Dissipation vs. PWM Frequency NOTE: For figures 4a and 4b – Operating Conditions: Vin = 230 Vrms, MI = 1.15, P.F. = 0.8, TA = 40°C. ZthSA limits ∆Tc rise during 1 minute overload to 10°C. page 4 Untitled-1 www.irf.com 4 10/17/97, 2:34 PM IRPT1053A 20 V GE = C ie s = C re s = C oes = C , C a pa cita n ce (pF ) 1200 0V , f = 1M H z C g e + C g c , C c e S H O R TE D C gc C ce + C gc V G E , G a te -to -E m itte r V olta ge (V ) 1400 1000 C ie s 800 C oes 600 400 C re s 200 A 0 1 10 V C E = 4 0 0V IC = 14A 16 12 8 4 A 0 0 100 10 20 30 40 Q g , To tal G a te C h a rge (n C ) V C E , C o lle cto r-to -E m itte r V o lta g e (V ) Figure 5a - Typical Capacitance vs. Collector-to-Emitter Voltage Figure 5b - Typical Gate Charge vs. Gate-to-Emitter Voltage 50,000 Resistance (ohms) TJ = 1 5 0 °C 10 TJ = 2 5 °C 40,000 30,000 20,000 10,000 109 97 103 91 85 79 73 67 61 55 49 43 37 31 0 25 I C , C o llecto r-to -E m itte r C u rre nt (A ) 100 Temperature (deg.C) V CC = 100V 5 µ s P U L S E W ID T H A 1 5 10 15 20 VG E , G a te -to -E m itte r V o lta g e (V ) Figure 5c - Typical Transfer Characteristics Figure 6 - Normal R-T Characteristics of the NTC Thermistor www.irf.com Untitled-1 page 5 5 10/17/97, 2:34 PM IRPT1053A Mounting Procedure Mounting Functional Information Heat Sink Requirements 1. Connect the driver board and the IRPT1053A 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. 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 1 2 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 123456789012345678901234567890 Figure 6. 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 ISI, IS2 and IS3, IS4 on the positive and negative DC rail respectively. Figures 4a-4b 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 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. 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 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. page 6 Untitled-1 www.irf.com 6 10/17/97, 2:34 PM IRPT1053A IRPT1053A Mechanical Specifications NOTE: Dimensions are in inches [milliimeters] 2.600 [66.04] 2.282 28X .650 .032 [0.81] [16.51] E5 G5 RT1 RT2 N/C .020 [0.51] THICKNESS E3 G3 E1 G1 P IS1 IS2 N RP [57.96] 2X R .210 [5.33] 2X R .080 [2.03] W E4 G4 E6 G6 N/C V U IS4 IS3 E2 G2 T 1.750 [44.45] R 1.419 [36.04] S 1.770 [44.96] 2.265 .209 [57.53] [5.31] .307 [7.80] Figure 7. www.irf.com Untitled-1 page 7 7 10/17/97, 2:34 PM IRPT1053A IRPT1053A IRPT1053A Mechanical Specifications .750 [19.05] .950 [24.13] .450 [11.43] .550 [13.97] .150 [ 3.81] .250 [ 6.35] .150 [ 3.81] .050 [ 1.27] .550 [13.97] .450 [11.43] .850 [21.59] 1.050 [26.67] NOTE: Dimensions are in inches [milliimeters] ALL PIN COORDINATE DIMENSIONS ARE BASIC .875 [22.23] PIN CENTER .000 [ 0.00] PIN CENTER PIN DIAGONAL 1.050 [26.67] .850 [21.59] .650 [16.51] .350 [ 8.89] .250 [ 6.35] .000 [ 0.00] .050 [ 1.27] .650 [16.51] .875 [22.23] .037 - .034 [.940 - .864] 28X .010 M A 28X ( .026 - .024) 28X .040 [1.02] MOUNTING SURFACE IN CLAMPED CONDITION A Figure 8. page 8 Untitled-1 www.irf.com 8 10/17/97, 2:34 PM IRPT1053A Figure 9. Power Module Circuit Diagram www.irf.com Untitled-1 page 9 9 10/17/97, 2:34 PM IRPT1053A Figure 10. Recommended Gate Drive Circuit page 10 Untitled-1 www.irf.com 10 10/17/97, 2:35 PM IRPT1053A Part Number Identification and Ordering Instructions IRPT1053A Power Module IRPT1053D 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 thermistor, 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. IRPT1053C POWIRTRAIN Integrated Power Module (IRPT1053A) and Driver-Plus Board (IRPT1053D) pre-assembled and tested to meet all system specifications. IRPT1053E Design Kit Complete POWIRTRAIN (IRPT1053C) with full set of design documentation including schematic diagram, bill of material, mechanical layoutof Driver Board, schematic files, Gerber files and design tips. www.irf.com Untitled-1 page 11 11 10/17/97, 2:35 PM IRPT1053A 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.), 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 3/97 page 12 Untitled-1 www.irf.com 12 10/17/97, 2:35 PM