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PD 6.101A IRPT2060A
PRELIMINARY
IRPT2060A
TM
Power Module for 3 hp Motor Drives
* 3 hp (2.2 kW) power output
Industrial rating at 120% overload for 1 minute
* * * * * * * * * *
180-240V AC single-phase input, 50/60 Hz Single-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. IRPT2060A Power Module
IRPT2060C IRPT2060A Power Module IRPT2060D Driver-Plus Board PWM variable frequency output
180-240V single-phase input
feedback (non-isolated)
PWM generator
Figure 2. The IRPT2060C control system
within a motor
page 1
IRPT2060A
The IRPT2060A Power Module
The IRPT2060A 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 single-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 25 m 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 IRPT2060A (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 (IRPT2060A) with a Driver-Plus Board (IRPT2060D).
Figure 3. IRPT2060C
page 2
IRPT2060A
Specifications
PARAMETERS Input Power
Voltage Frequency Current IFSM
VALUES
220V AC, -15%, +10%, single-phase 50/60 Hz 29A rms @ nominal output 400A 0-230V rms 3 hp (2.2 kW) nominal full load power 120% overload for 1 minute 11A rms nominal full load power 13.2A rms 120% overload for 1 minute 425V maximum 20A 50 kOhms 5% 3.1kOhms 10% 25mOhms 5% 10 s 50A peak
CONDITIONS
TA = 40C, RthSA = 0.41C/W 10 ms half-cycle, non-repetitive surge defined by external PWM control Vin = 230V AC, fpwm = 4 kHz, fo = 60 Hz, TA = 40C, RthSA = 0.41C/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 = 425V, 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 (refer 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
IRPT2060A
RthSA 100% Load Continuous 10-60 Hz
Thermal Resistance (RthSAC/W)
Power 120%
Power 100%
RthSA 120% Load (1 min.)10-60 Hz
3 hp (2.2 kW)
RthSA 120% Load (1 min.) Down to 3 Hz
PWM Frequency (kHz) - (Induction Motor Load)
Figure 4a. 3 hp/11A Output Heat Sink Thermal Resistance and Power Dissipation vs. PWM Frequency
RthSA 100% Load Continuous 10-60 Hz
Thermal Resistance (RthSAC/W)
Power 150%
Power 100%
RthSA 150% Load (1 min.)10-60 Hz 2 hp (1.5 kW) RthSA 150% Load (1 min.) Down to 3 Hz
PWM Frequency (kHz) - (Induction Motor Load)
Figure 4b. 2 hp/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)
Total Power Dissipation (Watts)
IRPT2060A
3000 2500
20
Cgc
2000
C ies
1500 1000 500 0
VGE , Gate-to-Emitter Voltage (V)
C, Capacitance (pF)
= 0V, V GE C ies = C ge + C res = C gc Coes= C ce +
f = 1MHz Cgc , C ce SHORTED
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
VGE , Gate-to-Emitter Voltage (V)
Figure 5c. Typical Transfer Characteristics Figure 6. Nominal R-T Characteristics of the NTC Thermistor
page 5
IRPT2060A
Mounting Procedure
Mounting
1. Connect the driver board and the IRPT2060A 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.
Functional Information
Heat Sink Requirements
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.
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. Single phase input connections made to pins 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
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1
2
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.
IRPT2060A
NOTE: Dimensions are in inches (millimeters)
Figure 8a. Power Module Package Outline
page 7
IRPT2060A
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. Power Module Package Outline
page 8
IRPT2060A
Figure 9. Power Module Circuit Diagram
page 9
IRPT2060A
Figure 10. Recommended Gate Drive Circuit
page 10
IRPT2060A
Part Number Identification and Ordering Instructions
IRPT2060A Power Module
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.
IRPT2060D Driver-Plus Board
Printed circuit board assembled with DC link capacitors. NTC in-rush limiting thermistor, high-power terminal blocks, surge suppression MOV, IGBT gate drivers, protection circuitry and low power supply. The PCB is functionally tested with standard power module to meet all system specifications.
IRPT2060C
Integrated Power Module (IRPT2060A) and Driver-Plus Board (IRPT2060D) pre-assembled and tested to meet all system specifications.
page 11
IRPT2060A
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. 11/97
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