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PD 6.099 IRPT2056A
PRELIMINARY
IRPT2056A
TM
Power Module for 3 hp Motor Drives
* 3 hp (2.2 kW) 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 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 -25C to 125C operational
Figure 1. IRPT2056A Power Module
IRPT2056C
IRPT 2056A Power Module IRPT 2056D Driver-Plus Board PWM variable frequency output
180-240V 3-phase input
feedback (non-isolated)
PWM generator
Figure 2. The power module and motor control system
within a
page 1
IRPT2056A
System Description
Power Module
The IRPT2056A 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 brake circuit uses 600V IGBT and freewheeling diode. The inverter section employs 600V, short circuit rated, ultrafast IGBT's 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 thermistors provide 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 IRPT2056C (Figure 3) provides the complete power conversion function for a 3 hp (2.2 kW) variable voltage, variable frequency AC motor controller. The combines the Power Module (IRPT2056A) with a Driver-Plus Board (IRPT2056D). The Design Kit, IRPT2056E includes the following: * Complete integrated power stage * Specification and operating instructions * Bill of materials * Electrical schematic * Mechanical layout of the Driver-Plus Board * Software transferrable file for easy design integration * Application information and layout considerations
Figure 3. IRPT2056C
page 2
IRPT2056A
Specifications
PARAMETERS Input Power
Voltage Frequency Current IFSM
VALUES
220V AC, -15%, +10%, 3-phase 50/60 Hz 15.4A rms @ nominal output 400A 0-230V rms 3 hp (2.2 kW) nominal full load power 150% overload for 1 minute 11A nominal full load power 16.5A 150% overload for 1 minute 400V maximum 20A 50 kOhms 5% 3.1kOhms 10% 25mOhms 5% 10 s 70A peak
CONDITIONS
TA = 40C, RthSA = 0.42C/W 10ms half-cycle, non-repetitive surge defined by external PWM control V in = 230V AC, fpwm = 4kHz, fo = 60 Hz, TA = 40C, RthSA = 0.42C/W
Output Power
Voltage Nominal motor hp (kW) Nominal motor current
DC Link
DC link voltage
Brake
Current
Sensor
Temp. sense resistance Current sense @ TNTC = 25C @ TNTC = 100C @ TSHUNT = 25C DC bus = 400V, VGE = 15V, line to line short Recommended short circuitshutdown current
Protection
IGBT short circuit time
Gate Drive
QG 120 nC (typical) @ VGE = 15V, refer figure 5b
Recommended gate driver
IR2133 (see Figure 10)
2500V rms -25C to 125C 1 Nm -40C to 125C at the pins (.06" from case) pin-to-baseplate, 60 Hz, 1 minute 95% RH max. (non-condensing) M4 screw type
Module
Isolation voltage Operating case temperature Mounting torque Storage temperature range
Soldering temperature for 10 sec. 260C maximum
page 3
IRPT2056A
0.6
Thermal Resistance (R thSAC/W)
300 RthSA 100% Load Continuous 10-60 Hz Power 150% 3 hp (2.2 kW) 200
0.4
0.3 Power 100% 0.2 RthSA 150% Load (1 min.) Down to 3 Hz 0.1 RthSA 150% Load 1 min.)10-60 Hz
150
100
50
0
1
4
8
12
16
20
24
0
PWM Frequency (kHz) - (Induction Motor Load)
Figure 4a. 3hp/11A output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency
0.9 0.8
Thermal Resistance (R thSAC/W)
RthSA 100% Load Continuous 10-60 Hz 2 hp (1.5 kW)
200 180 160 140 120
Total Power Dissipation (Watts)
0.7 0.6 0.5
Power 150%
100 0.4 0.3 0.2 0.1 0 Power 100% 80 RthSA 150% Load (1 min.) Down to 3 Hz RthSA 150% Load (1 min.) 10-60 Hz 60 40 20 0
1
4
8
12
16
20
24
PWM Frequency (kHz) - (Induction Motor Load)
Figure 4b. 2hp/8A output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency
NOTE: For Figures 4a and 4b: Operating Conditions: V in = 230V rms, MI =1.15, PF = 0.8, TA = 40C, Tj < 145C, Ts < 95C, ZthSA limits Tc during 1 minute overload to 10C page 4
Total Power Dissipation (Watts)
0.5
250
IRPT2056A
3000 2500
20
C, Capacitance (pF)
= 0V, V GE C ies = C ge + C res = C gc Coes= C ce +
f = 1MHz Cgc , C ce SHORTED Cgc
2000
C ies
1500 1000 500 0
VGE , Gate-to-Emitter Voltage (V)
VCC = 400V IC = 25A
16
12
8
C oes C res
1 10 100
4
0
0
20
40
60
80
100
120
140
VCE , Collector-to-Emitter Voltage (
Figure 5a. Typical Capacitance vs Collector-to-Emitter Voltage
Q , Total Gate Charge (nC)
G
Figure 5b. Typical Gate Charge vs Gate-to-Emitter Voltage
100
I C , Collector-to-Emitter Current (A)
TJ = 150C TJ = 25C
10
V CC = 50V 5s PULSE WIDTH*A
1 5 7 9 11
V , Gate-to-Emitter Voltage (V) GE
Figure 5c. Typical Transfer Characteristics Figure 6. Nominal R-T Characteristics of the NTC Thermistor
page 5
IRPT2056A
Mounting, Hookup and Application Instructions
Mounting
1. Connect the driver board and the IRPT2056A 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. 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.
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). 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.
Figure 7. Power Module Mounting Screw Sequence
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1
2
IRPT2056A
IRPT2056A Mechanical Specifications
NOTE: Dimensions are in inches (millimeters)
3.854 [97.89] 3.215 [81.66] 31X
HATCHED SURFACE .032 [0.81] .020 [0.51] THICKNESS
RT1 RT2 N/C G3 E3 G5 E5
F
.650 [16.51]
R
N
2.105 [53.47] 1.662 [42.21]
RP P IS1 IS2
G1 E1
2.040 [51.82]
BR
G7 IS4 IS3 G2 E2
G4 E4 G6 E6 N/C
U
S
T
V
W
.307 [7.80] .507 [12.87] HATCHED SURFACE E
Figure 8a. Package Outline and Mechanical Specifications
page 7
IRPT2056A
IRPT2056A Mechanical Specifications
NOTE: Dimensions are in inches (millimeters)
ALL PIN COORDINATE DIMENSIONS ARE BASIC 3.420 [86.87]
1.350 [34.29]
1.250 [31.75]
1.450 [36.83]
1.550 [39.37]
2X O .104 .002 [2.64 0.05] MINUS DRAFT X .400 O .010 G S A B-C
1.550 [39.37]
.650 [16.51]
.550 [13.97]
.450 [11.43]
.450 [11.43]
.750 [19.05]
.050 [ 1.27]
.350 [ 8.89]
.850 [21.59]
.350 [ 8.89]
.050 [ 1.27]
1.020 [25.91] PIN CENTER
2X C .800 [20.32] .400 [10.16]
.187 [4.75] .175 [4.45]
B
.000 [ 0.00]
2X R .250 [6.35] 4X O .260 [6.60] PIN CENTER 1.020 [25.91] PIN DIAGONAL .037 - .034 [.940 - .864] 31X O .019 O .010 31X ( .026 - .024) 31X .050 [1.27] M M E-F E-F G B-C
1.750 [44.45]
1.450 [36.83]
1.050 [26.67]
1.150 [29.21]
1.250 [31.75]
.950 [24.13]
.550 [13.97]
.950 [24.13]
.250 [ 6.35]
.150 [ 3.81]
.000 [ 0.00]
.250 [ 6.35]
HATCHED SURFACE
F
E
HATCHED SURFACE
MOUNTING SURFACE IN CLAMPED CONDITION
A
Figure 8b. Package Outline and Mechanical Specifications
page 8
IRPT2056A
RP
P
IS1
IS2 E1 G1
E3 G3
E5 G5
RT1
RT2
RS1 D7 D9 D11 D13
Q1
D1
Q3
D3
Q5
D5 RT
R S T
Q7
U V W Q2 D2 Q4 D4 Q6 D6
D8
D10
D12
RS2
N
BR G7
IS4
1S3 G2 E2
G4 E4
G6 E6
Figure 9. Power Module Circuit Diagram
Figure 10. Recommended Gate Drive Circuit
page 9
IRPT2056A
Functional Information
Heat Sink Requirements
Figures 4a through 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 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 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. 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 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 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.
page 10
IRPT2056A
Part Number Identification and Ordering Instructions
IRPT2056A Power Module
Chip and wire epoxy encapsulated module with 800V input rectifiers, 600V brake IGBT and freewheeling diode, 600V short-circuit rated, ultra-fast IGBT inverter with ultra-fast freewheeling diodes, NTC temperature sensing thermistor and current sensing low-inductance shunts.
IRPT2056D Driver-Plus Board
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.
IRPT2056C Complete
IRPT2056A Power Module and IRPT2056D Driver-Plus Board pre-assembled and tested to meet all system specifications.
IRPT2056E Design Kit
Complete (IRPT2056C) with full set of design documentation including detailed schematic diagram, bill of material, mechanical layout, schematic file, Gerber files and design tips.
page 11
IRPT2056A
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. 5/97
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