PD 6.117
PRELIMINARY
IRPT1060
ΤΜ
Integrated Power Stage 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
· Available as complete system or as sub-system
assemblies
Power Module
· 3-phase rectifier bridge
· 3-phase short circuit rated, ultrafast IGBT inverter
· 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
Driver-Plus Board
· DC bus capacitor filter with NTC inrush
current limiter
· IR2132 monolithic 3-phase HVIC driver
· On-board +15V and +5V power supply
· MOV surge suppression at input
· DC bus voltage and current feedback
· Protection for short-circuit, earth/ground fault and
overtemperature
· Terminal blocks for 3-phase input and output
connections
IRPT1060C
Figure 1.
The IRPT1060C
control system
within a motor
page 1
IRPT1060
System Description
The IRPT1060C
provides the complete
conversion function for a 1hp (0.75kW) variable frequency,
variable voltage, AC motor controller. The
combines a power module IRPT1060A with a Driver-Plus Board
IRPT1060D. Figure 1 shows the block diagram of the
within an AC motor control system.
The power module contains a 3-phase input bridge rectifier,
3-phase IGBT inverter, current sense shunts, and a thermistor. It
is designed for easy mounting to a heat sink. The Driver-Plus
Board contains DC link capacitors, capacitor soft charge function
using NTC thermistor, surge suppression MOVs, IGBT gate
drivers, DC bus voltage and current feedback signals, protetion
circuitry and local power supply. It is designed to mate with a
controller board through a single row header. Terminal blocks are
provided on the Driver-Plus Board for all end user line input and
motor output.
Output power is Pulse-Width Modulated (PWM) 3-phase,
variable frequency, variable voltage controlled by an externally
generated user-provided PWM controller for inverter IGBT
switching. The power supply offers the user non-isolated 5V and
15V to power the micro-controller.
The IRPT1060C offers several benefits to the drive
manufacturer listed below:
•
It greatly simplifies component selection, design of layout,
interconnection, gate drive, local power supply, thermal
sensing, current sensing and protection.
•
Gate drive and protection circuits are designed to closely
match the operating characteristics of the power
semiconductors. This allows power losses to be minimized and
power rating to be maximized to a greater extent than is
possible by designing with individual components.
•
It reduces the effort of calculating and evaluating power
semiconductor losses and junction temperature.
•
It reduces the manufacturer's part inventory and simplifies
assembly.
[
specifications and ratings are given for system
input and output voltage and current, power losses and heat sink
requirements over a range of operating conditions.
system ratings are verified by IR in final testing.]
The IRPT1060A Power Module
The IRPT1060A Power Module, shown in figure 2, is a chip
and wire epoxy encapsulated module. It houses input rectifiers
output inverter, current sense shunts and NTC thermistor. The
3-phase
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.
Figure 2.
IRPT1060A Power Module
page 2
IRPT1060
The IRPT1060D Driver-Plus Board
The IRPT1053D Driver-Plus board, shown in figure 3, houses
surge suppression MOVs on input, a switching power supply, a
DC bus filter capacitor with NTC inrush current limiter, an
IR2132J monolithic 3-phase driver IC, and protection and sensing
circuitry.
The inverter
gate drive circuit,
implemented with an IR2132J
monolithic 3-phase HVIC driver, delivers on/off gate drive
signals to the IGBTs’ gates, corresponding with input PWM
control signals IN1 through IN6. After power-up, RESET pin on
the J3 connector must be held low (with open collector
configuration) for at least 2µsec while all PWM signals, IN1
through IN6 are held high (off condition). A latch in the
protection circuitry is set high during a fault condition to trip the
IR2132J’s internal latch and shut down all PWM output gate
drive signals and cause the FAULT output pin on IR2132J to set
low and light the LED. The Fault diagnostic is an active low,
open drain output with a pull-up resistor. This signal is provided
on the J3 connector for
fault
feedback to external control logic.
The
protection circuitry
receives current signals from shunts
in positive and negative DC bus rail for
earth/ground fault
and
short-circuit
conditions. Any earth-fault signal is fed through an
opto-isolator to the protection circuitry. Current signal from
negative DC bus rail is provided on the J3 connector as
current
feedback,
I FB (0.045V/A). If filtering of this signal is required,
it should be done by adding a high-impedance buffer stage
between signal and filter. DC bus voltage is scaled down to
provided a voltage signal on the J3 connector as
voltage
feedback,
VFB (0.023 x Bus voltage). Thermal sense signal for
over-temperature
protection is obtained from a thermistor
housed inside the power module. The thermistor activates the
latch if the temperature of the power module’s IMS substrate
exceeds a set level.
The system is designed for 150% overload for one minute
while operating with the specified heat sink. The external
microcontroller should shut off PWM signals if the overload
condition persists for more than one minute.
The
switching power supply
employs the IR2152S self-
oscillating driver chip in a buck regulator topology to deliver
nominal 15V and 5V DC outputs, referenced to the negative DC
bus (N). The power supply feeds the gate drive and protection
circuits. The 15V and 5V outputs are available on the control
interface connector’s (J3) VCC and VDD pins for external
microprocessor and control logic supply.
Figure 3.
IRPT1060D Driver-Plus Board
page 3
IRPT1060
RS1
P
POWER MODULE
RT
Q1
Q3
Q5
Q2
Q4
Q6
RS2
R S T
N
RP P
IS4
IS3
IS1 IS2 G1 E1 G2 E2
G3 E3 G4 E4
G5 E5 G6 E6
U V W RT1 RT2
R S T
N RP
P
IS4
IS3
IS1 IS2 G1 E1 G2 E2
G3 E3 G4 E4
G5 E5 G6 E6
U V W RT1 RT2
NTC
Vcc
OPTO
ISOLATOR
DC
BUS
LINK
SC
EF OT
PROTECTION
LATCH
TRIP
Vcc
IR2132J
MOS GATE DRIVER
SWITCHING
POWER
SUPPLY
1 2
J3
J1
R S T
3φ INPUT
3
14
13 12
11
4
5
6
7
8
9
U V W
J2
V
DD
V
CC
N RESET VFB IFB
+5 +15
FAULT IN1 IN2 IN3 IN4 IN5 IN6
DRIVER BOARD
PLUS
Driver-Plus Board
3φ OUTPUT
Figure 4.
IRPT1060C Basic Architecture
page 4
IRPT1060
Specifications
PARAMETERS
Input Power
Voltage
Frequency
Input current
VALUES
220V, -15%, +10%, 3-phase
50/60Hz
6.2 Arms @ nominal output
100 A peak
0 - 230V
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
CONDITIONS
T
A
= 40°C, R
thSA
= 1.38°C/W
Initial bus capacitor charging
defined by external PWM control
V
in
= 230V, f
pwm
= 4kHz, f
o
= 60Hz
T
A
= 40°C, R
thSA
= 1.38°C/W
Z
thSA
limits
∆T
c
to 10°C during overload
Output Power
Voltage
Nominal Motor hp (kW)
Nominal motor current
Control Inputs
PWM input signals IN1...IN6
Pulsedeadtime
Minimum input pulse width
RESET
5V maximum, active low
0.8
µsec
typ. deadtime set by IR2132J
1
µsec
open collector, active low
CMOS, LSTTL compatible, open collector
max. deadtime set by external controller
pin 14 of control interface connector
pull down for
⊕
2µsec to release latch
T
C
= 25°C
T
C
= 25°C
Case temperature
user to ensure rating not exceeded for >30 sec.
output terminals shorted
Protection
Output current trip level
Earth/gnd fault current trip level
Overtemperature trip level
Maximum DC link voltage
Short circuit shutdown time
30A,
±
10%
36A,
±
10%
100° 5%
C,±
400V
2.5
µsec
typical
0.045V/A
0.023 typical V/V
BUS
5V, active low
15V,
±
10%
5V,
±
5%
60mA
Feedback Signals
Current feedback (IFB)
DC bus voltage feedback (VFB)
Fault feedback (Fault)
On Board Power Supply
V
CC
V
DD
I
CC
+ I
DD
max. limit specified is available on control
interface connector J3 for external use
pin to base plate isolation, 60Hz, 1 minute
95%RH max. (non-condensing)
M4 screw type
95%RH max. (non-condensing)
Module
Isolation voltage
Operating case temperature
Mounting torque
2500V rms
-25°C to 125°C
1 Nm
0 to 40°C
-25 to 60°C
System Environment
Ambient operating temp. range
Storage temperature range
page 5
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