PD 6.0934 International TaRRectifier seamnary IRPT2051A POWIRTRAIN 3 hp (2.2 kW) power output Industrial rating at 150% overload for 1 minute 390-4B0V 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-ic-boseplate isolation 2500Y rms Easy-to-maunt hwo-screw package Case temperature range -25C to 125C operational Figure 1, IRPT2051A Powe: Module IRPT2051C POwIRTRAIN 4 | [ 4RPT 051A meth ' 380 - 480 V Power requancy: J -phose impy: Assembly vo Inge oi L_yif iRPT 20510 Driver-Phis Board anes ns rn ; TT --5 . | PAM, *gedhack SF orncessi k generator Press J Le i | keyboard l k eee eee EE Exlerned Control Functions Figure 2. Ike RFTZ051C POWTEIRAIN within a motor contra: eystern Revised 5/97 page |IRPT2OS51A System Description Power Module The TRPT20517A power mocule shown in Figure tis au chip and wire epoxy encapsulazed madule, I houses input rectifiers, oUpul inverter, current sense shunts and NTC thermistor. The 3-phase input bridge rectifiers are rater at |G00. The brake circuit uses L200 IGBT und treewheeling diode. The inverter section employs |200. short circuit rated, ultrafast IGBTs aad ultrafast freewheeling diodes. Current sensing is achieved through 25 m2 law inductance shuats provided in lhe posidive and negative DC bes ru, The NTC taermistor provides lcmperature sensing capability. The lead spacing on the power module meets UL&40 pollution level 3 requirements, The power circuit and layout wiltin the module are carefully designed ta minimize inductance in the power path, to reduce noise during inverter operation and to improve the inverter efficiency. The Driver-P/us Roant required to run the siverter can be soldered to the power moduie pins. 1hus minimizing assembly and alignment, The power module is designed to be a mounted to a heat sink with two screw mount onsitions, in onder to ensure good thermal contact beiween Lhe madule substrate end the heat sartk. poge 2 International TOR Rectitier POWIRTRAIN and Design Kit The IRPT2U51C POMARYRAIN (Figure 33 provides the complete power conversion function fora 3 hp (2.2 kW) variable voltage, variable frequency AC motor comlrosler. The PowIR re Ame combincs the Power Module (IRPT205 14) with a Driver-Pius Board (IRPT2051D). The POWERTRAIN Desien Kit, IRPT205 1F incluces the following: + Complete POWERTRAIN integrated power stage Specification and operating instructions + Bill of materials Blectrical sclemuilic + Mechanical layout of the Driver-Piss Board + Software transferrable file for casy design intesratian + Applicatian information and layout considerabons Figure 3. IRPT2051C POWIRIRAIYInternationa TOR Rectifier Specifications IRPT2O51A PARAMETERS VALUES. CONDITIONS Input Power | Voltage 7 Frequency 380V, -15%, 48CV +10%, 3-phase 50/60 Hz Current 8.26A mms @ nominal outgut Ta = 40C, Risa = O.5 9 le5aq 400A _ 10 ms nal-cycle, nonrepetitive surge Ouiput Power [| Voltage _ 0. 480 rms defined by external PWM control Naminal motor ho {kv a hp (2.2 kW} nom nol cull load powe- 150% overload for | minute moler cumrend 5.94 nominal full load power 685A 740% overload for 1 minute Vin = 440V AC, frum = 4 kriz, fy= 60 Hz, Neminal Ta = 40C, Rusa = O.59C/W shutdown current DC Link BC link voltage 850 maximurn Brake Current 10.54 Sensor Temp sense resishance 50 kOhms +4% @ Thre = 25C 3.1 kOhms 410% @ Tne = 100C Current sense 25mOhms +5% & Tepe = ZOO Profection ISBT short circuit tee Sus DC Sus = 8450, Ver = 154, line to line short Racommended short circuit. 4CA peak , Gale Drive Oe we eee rece eed 52 nc [typical] @ Veg = 15V, refer figure Sb Reco mmended gate driver IR2233 (see Figura 10} reter design kit IRPTZ051E Module Slorage temperature range 40C +o 150C Isolation valtage 2500 rms pints-baseplaie, 69 Hz, | minute Operating case tamperature -25C to 126C 95% RH max. {nen-cendensing} Mounting torque 7 Nm Ma screw hype Soldering temparature for 10 sac. 260C maximum at the pins [.06" fram case) page 3IRPT2ZO51A nlernationa Tar Rectitie: OF 300 - a = 08 La a ee sa (00% Load Continuous a 7250 2 a 07 4. al 3 hp B 60 Hz oe wy = 208 aN IN --T 200 8 P| Al we g 2 05tp Pe Lt 3 eM ower = 15 oN Weis be ~~ q150 g e O04 < a = on oT \ SE nan: = m 0.4 ye = = Pp pt 100 o = 1oo%e - | ey 0.2 oe | - ; . . FSO | oO. Rca 150% Load {1 Mir |p, 54 150% Lead (7 min joo =] Dawn to J Hz 10-60 Hz Pe | | | | | 1 | | n 5 Me 1 4 8 \2 14 20 24 PAA Fraquency (kHz} - Induction Motor Load: Figure 4a. 3 hp/5.94 Output Heat Sink Thermal Resistance and Power Dissipation vs. PVM Fraquancy 1.4 290 IN - = +180 3 12 Sy = = o N Risa 100% Load Continuous - tiso = ee 2 hp = ww 10.69 Hz 1 1 a SWIPE 6 a , a \ : = ws Power Ee ou one a] 8 0.8 ~ ll * perp 120 2 3 ~ _ Lee a we PJ a7 +100 2 06 att at MN pd Pe 2 5 N =~ | Ph 440 T = ne 2 ~ - Power | _ ~ P| io 0.4 100% Ea perl 4 ~ A so | J ZN, +40 | 02 Rinsa 130% Load (1 min.) Riga, 130% Load [1 min.; Down to 3 Hz NJ 10-40 Hz 720 0 | | | | | | | | 4, ] 4 8 |? 16 20 24 PYM Frequency {<Hz] (Induction Motor Load} Figure 4b. 2hp/4.2A Cutput Heat Sink Thermal Resistance and Power Dissipation vs. PVM Frequency NOTE: For figures 4a and 4b: Qperating Conditions: V,, = 460V,,,. Ml = 1.15, PF-O.8, Ta= 40C, T;= 144C, T3= 95C, Zsa limits AT, during 1 minute averload to 10C poge 4Interna oral Tor Rectifier GE=EF. = er = Ca Cor. Con SHORTED reo = Coc * G, Capacilance (pF) 1 t 1 Woe, Collecior-tp-Emitter Vattege () Figure 5a. Typical Cupacitance vs Collector-toEmittar Vohace ig, Callactor-to-Emittar Cusrent [A} cc = 100" i 1 1s zo Vag Gate-to-Emitier Voltage (} Figure 5c. Typical Transfer Characteristics Resistance (ohms) IRPT2O051A Vg_e, Gate-fo-Em itler Yottaga {) o eo ao w Gy, Total Gata Charge (nG) Figure Sb. Tysical Gate Charge vs Gatato-Emiter Voltage $ g 3 al 8 8 a hte} | mete 8 g =~ . ba i . ot ae a PBB ERR SEE SE g = moo Temperature (dey.C} Figure 6 Nominal R-T Characteristics of the NTC Thermistar poge 3IRPT2O51A niernational TOR rectifier Mounting, Hookup and Application Instructions Mounting L. Connect the driver board and the TRPT204514 module. 2. Remove all pardcles and gmt irors the beat sink aod power suhstrate. 3. Spread a 004" to O05" layer of silicone prease on the heat sink, covernng the entire urea (hat the puwer substrate will occupy. Recommended heat sink flatness in 0] inch/nch and Total Indicator Readout (TIR) of .003 inch below substrate. 4. Place the power substrate ante the heat sink with the mounting holes aligned and press it firmly ime the silicone erease. . Insert the two M4 mounting screws through the PCB and power madole and into the heat sink and tighten the screws to 1 Nm terque. Figure 7. Power Madule Maunting Screw Sequence page 6 Power Connections The power module pin designation, functicn and other detuils can he obtained from the package outline in Figure and circu diagram in Figure 9. 3-phase input connections are made to pins R, S and T and inverter output connections are made to pins Ly and W. Positive DC bus and brake IGBT collector connections ar brought ont 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 bas capacitor seft charging iraplementation option. Fhe current shunt terminals ar connected ta pins [8], TS2 and I83, [54 on the positive and negative DC ruils, respectively.nternational IRPT2O51A TaR Rectifier IRPT2051A Package Outline and Mechanical Specifications NOTE: Dimensions are ig inches (mullimeters) PUD ESEL BALE aE aie car [a1] 1x Cat [5.51] THIC<NESS oF vagy aot 1287) FATSWED SURFACE [- = - Figure Ba. Package Ouilina and Machanical Specifications page 7IRPT2O51A Internatiora TOR Rectifier ALL FIN SOOPDINATE DIMENSIONS 455 Bau > + z F = oss SAa24 we = no RR aS2 a8 S Ra TAB 1 902 fe58 a6 gop [tad ety | J WHUS OORT NATO \ ; pete on Sle Soho pe centre | 187 [2 Pal a ITB e as" (aero 24 { ; 260 0,90] ay : ee , LL j a 2XR 350 'A 59] 4003 265 [2.62] "| 7h CENTER . HH - FE a #t 7600 [25.97] f | ( w\ 1h CRAGUNAL g 8 cr =-=s 5p & FREE tag. ca + . S3 Be & SEAR 2 2 45 2o3 3 2 x88 Fog & 252 % & $828 QUA M06 - Ob eee TX 60 [4 27] ha HATCHED suRFAcE LF -" | ee Fa PGHEG S.5F eG E ize SUShACE IN SLAM FED CONDIT OM = | = Figure 8b, Paccage Outline and Mechanical Specifications sage &International TGR Rectitier RP a = PIS) B2 ES) E3G3 Fa GS IRPT2051A RTI RT2 BRG? Sd 18362 E2 Gd Bd G4E6 Figure 9. Power Module Circuit Diagram Es a Ee a C Ons 3 2 san * - Wee, Yo n Soy Hy, Ha, Ay H } | the tet a ! Hye sr | 2 os : PM ne 3 re L, Hoy | tas ty TS +) . aw a of bee Yt - wb LET We a f EN tL 7* Hes 4 AAAS Hla } aw hae tT A lcao Ve F L 7 om a n ow ge tp rr <| ' JB om " Nal } he Flt. kt Ls ws a xn fy ys AN - ie ; Ae | Current eroee mPower Modu: Figure 10. Recommendad Gate Drive Circuit page ?IRPT2051A Internationa Ter Rectifier Functional Information Heat Sink Requirements Figures 4a through 4b show the thermal resistanec of the heat sink required fur vanous autput power levels and pulse-width- madulated (PWM? switching frequencies. Maximum total losses uf the unit are alsa shown. This dara is based on the toliowing key operating condions: The maximum continucus combined lusses 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 inverler at full pulse-width modulation under overload set the {nerement 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 fequency, IGBT junction temperature tends to follow the instantaneous fluctuations of the qutput current. Thus, peak junction temperature rise increases as wutput frequency decreases. page 10 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 MS exceeds a set bevel can be implemented. The nominal resistance vs. temperature characteristic of the thermistor is given in figure 6. Voltage Rise During Bruking The metor will feed energy back to the DC link dunng regenerative braking, forcing the bus voltage to rise above the level defined by the input vultage. Deceleration of the motar must be controlled by appropriate PWM control to keep the DC bus voltage within the rated maximum value. For high inertial juads, or for very fast deceleration rates, this can be achieved by connecting an cxtemal braking resistur across P and BR and controlling the brake JGBT switching when the bus voltage exceeds the allowahte limit.International TOR Rectifier IRPT2051A Part Number identification and Ordering Instructions IRPT2051A Power Module Chip und wire epoay encupsulaled module with 1600 input rectifiers. L2COV brake DOBT and treewhecling diods. L200 shond-circoit rated, wWerafiist GBT inverter with ultrafast freewheeling diades, KC temperature sensing thermistor and current sensing low-induetance shunts. IRPT2051C Complete powiRrrain IRPT20514 Power Module and IRPT2051D Driver-Pties Board pre assembled and tested to meet all system specrficauons. IRPT2051D Driver-Plus Board Printed circuit board assembled with DAC link capacitors, NTC ia ash linting thermister, bigh power terminal blocks, surge suppression MOVs, IGBT gate drivers, protection circuitry and jow power supply. The PCB is functionally tested with standard power mdaule to sneet all system specifications. IRPT205 1E Design Kit Complete POWERYRAIN (IRPT2051C), with fuil set of design documentation including detailed schematic diagram, bill of mmaienal, mechuntcal jayout, schematic file, Gerber files and design tips. pege 11IRPT2Z051A International Tear Rectifier International TeaR Rectitier WORLD HEADQUARTERS: 233 Kansas St., Et Segundo, California 90245, Tel: (210) 322 3334 EUROPEAN HEADQUARTERS: Hurst Graen, Oxted, Surray RH6 9B. UK Tal: +4 44 1883 792020 IR CANADA: 7321 Victoria Park Ave., Suite 201, Markham, Ontario LSR 228, Tel: (905) 475 1897 IR GERMANY: Saalburgstrasse 187, 61950 Bad Homburg Tal: +- 49 6172 96590 IR ITALY: Via Liguria 49, 16071 Borgaro, Torino Tel: +4 39 11 4510111 IH FAR EAST: 171 (K&H Bldg}, 3-36-4 Nishi-ikabukuro 3-Choma, Toshima-ku, Tokyo Japan Tel: 61 3 3983 0086 IR SOUTHEAST ASIA: 315 Outram Road, #10-02 Tan Boon Liat Building, Singapore 0316 Tel: 65 221 8371 hitp. www irfcon Osta and specications subject fa change without notice. S/O? page 12