Datasheet IRPT2056A Datasheet (IOR)

Page 1
IRPT2056A
PD 6.099
PRELIMINARY
Power Module for 3 hp Motor Drives
· 3 hp (2.2 kW) power output
Industrial rating at 150% overload for 1 minute
· 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
IRPT2056A
Figure 1. IRPT2056A Power Module
IRPT2056C
PWM
180-240V
3-phase input
Figure 2. The power module and within a
IRPT 2056A
Power
Module
IRPT 2056D
Driver-
Plus
Board
PWM
generator
motor control system
variable
frequency
output
feedback (non-isolated)
page 1
Page 2
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
page 2
Figure 3. IRPT2056C
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IRPT2056A
Specifications
PARAMETERS VALUES CONDITIONS
Input Power
Voltage 220V AC, -15%, +10%, 3-phase Frequency 50/60 Hz Current 15.4A rms @ nominal output TA = 40°C, R I
FSM
400A 10ms half-cycle, non-repetitive surge
Output Power
Voltage 0-230V rms defined by external PWM control Nominal motor hp (kW) 3 hp (2.2 kW) nominal full load power Vin = 230V AC, f
Nominal motor current 11A nominal full load power T
150% overload for 1 minute fo = 60 Hz,
= 40°C, R
16.5A 150% overload for 1 minute
A
DC Link
DC link voltage 400V maximum
Brake
Current 20A
Sensor
Temp. sense resistance 50 kOhms ±5% @ T
3.1kOhms ±10% @ T
Current sense 25mOhms ±5% @ T
Protection
IGBT short circuit time 10 µs DC bus = 400V, VGE = 15V,
line to line short Recommended short circuit- 70A peak shutdown current
Gate Drive
Q
G
Recommended gate driver IR2133 (see Figure 10)
120 nC (typical) @ VGE = 15V, refer figure 5b
Module
Isolation voltage 2500V rms pin-to-baseplate, 60 Hz, 1 minute Operating case temperature -25°C to 125°C 95% RH max. (non-condensing) Mounting torque 1 Nm M4 screw type Storage temperature range -40°C to 125°C Soldering temperature for 10 sec. 260°C maximum at the pins (.06" from case)
thSA
thSA
NTC
NTC
SHUNT
= 25°C
= 100°C
= 25°C
= 0.42°C/W
= 4kHz,
pwm
= 0.42°C/W
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Page 4
IRPT2056A
0.6
0.5
°C/W)
thSA
0.4
0.3
Power 150%
R
100% Load Continuous
thSA
10-60 Hz
3 hp (2.2 kW)
300
250
200
150
Power 100%
Thermal Resistance (R
0.2
0.1
R
150% Load (1 min.)
thSA
Down to 3 Hz
0
1 4 8 12 20
R
150% Load
thSA
1 min.)10-60 Hz
16 24
100
50
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
0.7
°C/W)
thSA
0.6
R
100% Load Continuous
thSA
10-60 Hz
Power 150%
2 hp (1.5 kW)
200
180
160
140
120
0.5 100
0.4
0.3
Thermal Resistance (R
0.2
0.1
Power 100%
R
150% Load (1 min.)
thSA
Down to 3 Hz
R
150% Load (1 min.)
thSA
10-60 Hz
80
60
40
20
Total Power Dissipation (Watts)
Total Power Dissipation (Watts)
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: Vin = 230V during 1 minute overload to 10°C
page 4
, MI =1.15, PF = 0.8, TA = 40°C, Tj < 145°C, Ts < 95°C, Z
rms
0
thSA
limits T
c
Page 5
IRPT2056A
(
3000
=
0V,
2500
2000
1500
1000
V
GE
C
=
ies ge gc , ce
C
=
res
C
=
oes ce gc
C
C C C
ies
+ C
gc
+ C
f = 1MHz
C SHORTED
C, Capacitance (pF)
C
500
0
1 10 100
100
oes
C
res
V , Collector-to-Emitter Voltage
CE
Figure 5a. Typical Capacitance vs
Collector-to-Emitter Voltage
20
CC
V = 400V
C
I = 25A
16
12
8
4
GE
V , Gate-to-Emitter Voltage (V)
0
0 20406080100120140
Q , Total Gate Charge (nC)
G
Figure 5b. Typical Gate Charge vs
Gate-to-Emitter Voltage
T = 150°C
J
T = 25°C
10
C
I , Collector-to-Emitter Current (A)
1
5 7911
V , Gate-to-Emitter Voltage (V)
GE
Figure 5c. Typical Transfer Characteristics Figure 6. Nominal R-T Characteristics of the
J
V = 50V
CC
5µs PULSE WIDTH•
A
NTC␣ Thermistor
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Page 6
IRPT2056A
0
0
0
0
0
0
0
0
0
0
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.
2345678901234567890123456789
2345678901234567890123456789
2345678901234567890123456789
2345678901234567890123456789
2345678901234567890123456789
2345678901234567890123456789
2345678901234567890123456789
1 2
2345678901234567890123456789
2345678901234567890123456789
2345678901234567890123456789
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 (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.
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Page 7
IRPT2056A Mechanical Specifications
NOTE: Dimensions are in inches (millimeters)
IRPT2056A
2.105
[53.47]
1.662
[42.21]
3.854
[97.89]
3.215
[81.66]
R
N
T
S
P
E1
G1
RP
IS2
IS1
E2
G2
IS3
IS4
G7
BR
E5
E3
G5
G3
E4
G4
V
U
N/C
RT2
RT1
N/C
W
E6
G6
Figure 8a. Package Outline and Mechanical Specifications
HATCHED SURFACE
.032 [0.81]
31X
.020 [0.51]
THICKNESS
2.040 [51.82]
HATCHED SURFACE
F
.650
[16.51]
.307
[7.80]
.507
[12.87]
E
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Page 8
IRPT2056A
IRPT2056A Mechanical Specifications
NOTE: Dimensions are in inches (millimeters)
ALL PIN COORDINATE DIMENSIONS ARE BASIC
3.420 [86.87]
2X .104
MINUS DRAFT X .400
.002
±
Ø
±
[2.64 0.05]
.010 A B-C
S
Ø
G
.800 [20.32]
.400 [10.16]
4X .260 [6.60]
Ø
HATCHED SURFACE
.050 [ 1.27]
.450 [11.43]
.350 [ 8.89]
.550 [13.97]
C
31X ( .026 - .024)
31X .050 [1.27]
F
.650 [16.51]
1.250 [31.75]
1.550 [39.37]
.950 [24.13]
1.450 [36.83]
1.750 [44.45]
.050 [ 1.27]
.000 [ 0.00]
.250 [ 6.35]
.150 [ 3.81]
.350 [ 8.89]
.450 [11.43]
.250 [ 6.35]
.550 [13.97]
.850 [21.59]
.750 [19.05]
1.050 [26.67]
.950 [24.13]
Figure 8b. Package Outline and Mechanical Specifications
1.350 [34.29]
1.450 [36.83]
1.550 [39.37]
1.020 [25.91]
PIN CENTER
.187 [4.75]
2X
.175 [4.45]
.000 [ 0.00]
2X R .250 [6.35]
PIN CENTER
1.020 [25.91]
PIN DIAGONAL
.037 - .034
[.940 - .864]
1.250 [31.75]
1.150 [29.21]
31X
M
.019 E-F G B-C
Ø
.010 E-FM
Ø
E
HATCHED SURFACE
MOUNTING SURFACE IN CLAMPED CONDITION
A
B
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Page 9
IRPT2056A
RP P
D7 D9 D11 D13
R S T
D8 D10 D12
N BR G7 IS4 1S3 G2 E2 G4 E4 G6 E6
IS1 IS2 E1G1
RS1
Q7
RS2
E3 G3 E5 G5 RT1 RT2
Q1
D1
Q2
D2
Figure 9. Power Module Circuit Diagram
Q3
Q4
Q5
Q6
D5
RT
U V
W
D6
D3
D4
Figure 10. Recommended Gate Drive Circuit
page 9
Page 10
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.
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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.
IRPT2056C Complete
IRPT2056A Power Module and IRPT2056D Driver-Plus Board pre-assembled and tested to meet all system specifications.
IRPT2056D Driver-
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.
Plus
Board
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.
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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 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
page 12
http://www.irf.com/ Data and specifications subject to change without notice. 5/97
IR ITALY: Via Liguria 49, 10071 Borgaro, Torino Tel: ++ 39 11 451 0111
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