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Fuji Electric IGBT-IPM X Series, Applications Manual

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Fuji Electric IGBT-IPM X Series Applications Manual Download Page 65

MT6M15962a

© Fuji Electric Co., Ltd. All rights reserved.

Figure 4-4 shows the typical application circuits of P630, P631, P636 and P644 (7in1, with built-in 

brake).

4-5

Fig.4-4 Typical application circuits of P630, P631, P636 and P644 (7in1)

(b) When not using the upper arms alarm

(a) When using the upper arms alarm

Summary of Contents for IGBT-IPM X Series

Page 1: ...Fuji Electric Co Ltd All rights reserved MT6M MT6M15962a Application Manual Fuji 7th Generation IGBT IPM X Series Oct 2021...

Page 2: ...ecifications All applications described in this manual exemplify the use of Fuji s products for your reference only No right or license either express or implied under any patent copyright trade secre...

Page 3: ...an environment during transportation are described in the specification sheet There conditions shall be kept under the specification 2 Assembly environment Since this power module device is very weak...

Page 4: ...l marking 2 2 2 Description of terms 2 3 Chapter 3 Description of functions 3 1 1 List of functions 3 2 2 Description of functions 3 3 3 Truth table 3 8 4 Block diagram of IPM 3 9 5 Timing chart 3 11...

Page 5: ...recautions for use 6 1 4 1 Main power supply 6 2 2 Control power supply 6 3 3 Protection functions 6 5 4 Power cycling capability 6 7 5 Others 6 7 Chapter 7 Troubleshooting 7 1 1 Troubleshooting 7 2 2...

Page 6: ...5962a 1 Features of the IGBT IPM 1 2 2 Part number and lot No 1 3 3 Line up 1 5 4 Features of each package 1 7 5 Structure 1 15 Chapter 1 Features and structure Fuji Electric Co Ltd All rights reserve...

Page 7: ...when an OC SC UV and or TjOH occur Additionally the IPM initiates a safe soft stop of the system 1 1 See Chapter 3 Description of functions for details of protective functions of each IPM 1 3 Built in...

Page 8: ...t number ex 6MBP50XBA120 50 Table 1 1 shows how to read the part number of the X series IPM 6 MBP 50 X B A 120 50 IGBT Switch number Type of module Current rating IGBT Chip generation Package Suffix V...

Page 9: ...d the lot No of the X series IPM 20 1 001 Production year Production month Serial number 19 2019 1 January 001 999 20 2020 2 February 21 2021 9 September O October N November D December Fig 1 1 Indica...

Page 10: ...50 7MBP100XFN065 50 P638 6MBP50XGA065 50 6MBP75XGA065 50 6MBP100XGN065 50 6MBP150XGN065 50 P630 6MBP50XDA065 50 7MBP50XDA065 50 6MBP75XDA065 50 7MBP75XDA065 50 6MBP100XDA065 50 6MBP100XDN065 50 7MBP1...

Page 11: ...MBP25XGA120 50 6MBP35XGA120 50 6MBP50XGN120 50 6MBP75XGN120 50 P630 6MBP25XDA120 50 7MBP25XDA120 50 6MBP35XDA120 50 7MBP35XDA120 50 6MBP50XDA120 50 6MBP50XDN120 50 7MBP50XDA120 50 7MBP50XDN120 50 6MBP...

Page 12: ...the same as the control terminals Therefore it is possible to solder the main terminals and control terminals to the same PCB Screw size for the heat sink is M4 Protective function is applied to the...

Page 13: ...e it is possible to solder the main terminals and control terminals to the same PCB Screw size for the heat sink is M4 Compatible mounting dimensions with the R IPM series P619 package Protective func...

Page 14: ...height is the same as the control terminals Therefore it is possible to solder the main terminals and control terminals to the same PCB Screw size for the heat sink is M4 The package outline drawing...

Page 15: ...nals are flat type solder pin and the height is the same as the control terminals Therefore it is possible to solder the main terminals and control terminals to the same PCB Screw size for the heat si...

Page 16: ...older the main terminals and control terminals to the same PCB Screw size for the heat sink is M4 Two types of protrusions with different heights are provided on the upper surface of the lid The heigh...

Page 17: ...k is M4 common with the main terminals All electrical connections are done with screws and connectors thus no soldering is required and easy to remove The package outline drawing is shown in Figure 1...

Page 18: ...s They are insulated internally and are not connected to any object Unit of dimensions mm 4 7 P630 package 6in1 7in1 with upper and lower arm alarm signal output The line up is 50A to 250A for 650V an...

Page 19: ...connections to be made securely Screw size for the heat sink is M5 common with the main terminals All electrical connections are done with screws and connectors thus no soldering is required and easy...

Page 20: ...t Material main Remarks 1 Base Plate Cu Ni plating 2 Main Terminal Cu First coating Ni plating Surface Sn based plating 3 Control Terminal Brass First coating Ni plating Surface Sn based plating 4 Cas...

Page 21: ...ass First coating Ni plating Surface Sn based plating 4 Case PPS resin UL 94V 0 5 Lid PPS resin UL 94V 0 6 Isolation substrate Ceramic Cu 7 IGBT chip Silicon Not shown 8 FWD chip Silicon Not shown 9 W...

Page 22: ...t coating Ni plating Surface Sn based plating 4 Case PPS resin UL 94V 0 5 Lid PPS resin UL 94V 0 6 Isolation substrate Ceramic Cu 7 IGBT chip Silicon Not shown 8 FWD chip Silicon Not shown 9 Wiring Al...

Page 23: ...inal Brass First coating Ni plating Surface Sn based plating 4 Case PPS resin UL 94V 0 5 Lid PPS resin UL 94V 0 6 Isolation substrate Ceramic Cu 7 IGBT chip Silicon Not shown 8 FWD chip Silicon Not sh...

Page 24: ...e Au plating 4 Case PPS resin UL 94V 0 5 Lid PPS resin UL 94V 0 6 Isolation substrate Ceramic Cu 7 IGBT chip Silicon Not shown 8 FWD chip Silicon Not shown 9 Wiring Aluminum 10 Printed Circuit Board P...

Page 25: ...e PPS resin UL 94V 0 5 Lid PPS resin UL 94V 0 6 Isolation substrate Ceramic Cu 7 IGBT chip Silicon Not shown 8 FWD chip Silicon Not shown 9 Wiring Aluminum 10 Printed Circuit Board PCB Glass reinforce...

Page 26: ...e PPS resin UL 94V 0 5 Lid PPS resin UL 94V 0 6 Isolation substrate Ceramic Cu 7 IGBT chip Silicon Not shown 8 FWD chip Silicon Not shown 9 Wiring Aluminum 10 Printed Circuit Board PCB Glass reinforce...

Page 27: ...P630 Package Screw standard Terminal tab thickness B Nut depth C Screw hole depth D P638 M4 0 8 3 5 8 0 0 5 P630 M4 0 8 3 5 8 5 0 5 P631 M5 1 4 9 0 0 5 Table 1 5 IPM main terminal specifications Unit...

Page 28: ...P636 P636 package has two types of protrusions with different heights 2 5 mm and 1 0 mm on the lid The PCB height can be set to 18 5 mm or 17 0 mm by utilizing these protrusions Fig 1 18 Selecting fr...

Page 29: ...MT6M15962a 1 Description of terminal marking 2 2 2 Description of terms 2 3 Chapter 2 Description of terminal marking and terms Fuji Electric Co Ltd All rights reserved 2 1...

Page 30: ...ignal output GND VCC V V Ground reference for the V phase control power supply V arm control power supply positive terminal Vin V V arm control signal input ALM V V arm alarm signal output GND VCC W W...

Page 31: ...nd GND terminal Alarm signal voltage VALM Maximum voltage between the ALM and GND terminal Alarm signal current IALM Maximum current between the ALM and GND terminal Tvj warning signal voltage VWNG Ma...

Page 32: ...Refer to Figure 2 1 Turn off time toff The time from when the input signal rise above the input threshold value Vinth off until the collector current of IGBT become 10 of predetermined current Refer...

Page 33: ...g hysteresis TjWH Temperature drop required for chips warning temperature operation to reset Under voltage protection level Vuv Threshold voltage for under voltage protection Under voltage protection...

Page 34: ...energy of the FWD during reverse recovery Input current Iin Maximum current into the Vin terminals Soft shutdown Turn off operation when protective operation is activated Softer turn off than normal 2...

Page 35: ...MT6M15962a Fuji Electric Co Ltd All rights reserved Fig 2 1 Switching times 2 7 Fig 2 2 Alarm signal output hold time tALM 2 6 Operation explanatory diagram 10 td on td off...

Page 36: ...MT6M15962a Fuji Electric Co Ltd All rights reserved Fig 2 3 Warning Timing Diagram 2 8 Fig 2 4 Overcurrent protection delay time tdOC...

Page 37: ...MT6M15962a Fuji Electric Co Ltd All rights reserved Fig 2 5 Short circuit protection delay time tdSC 2 9 Fig 2 6 Dead time tdead Turn off side Turn on side...

Page 38: ...5962a 1 List of functions 3 2 2 Description of functions 3 3 3 Truth table 3 8 4 Block diagram of IPM 3 9 5 Timing chart 3 11 Chapter 3 Description of functions Fuji Electric Co Ltd All rights reserve...

Page 39: ...ower arms Upper arm Lower arm Drive UV TjOH OC SC ALM ALM WNG 7in1 P644 P636 P630 P631 Drive IGBT drive circuit UV Control power supply under voltage protection TjOH IGBT chips over heating protection...

Page 40: ...surge voltage 2 2 IGBT and FWD for brake IGBT and FWD for brake circuit are integrated in and the collector terminal of the IGBT is connected to the output terminal B as shown in Figure 3 1 The regen...

Page 41: ...reduced when the IGBT is turned off by the protection function in various kinds of abnormal modes This soft shutdown suppresses the surge voltage during turn off and prevents the IPM from being destro...

Page 42: ...e IGBT will not turn on If the control input signal is OFF state after the alarm signal output period tALM has elapsed the protection operation is reset and normal operation is resumed On the upper ar...

Page 43: ...n function is activated and an alarm signal is output The SC status alarm signal output period tALM is approximately 2ms Protection operation is reset after 2ms tALM and normal operation is resumed if...

Page 44: ...uilt in the previous IPM series is not built in this X series The IGBT chip is protected by the TjOH protection function 2 9 Temperature warning output function TjW Temperature warning output function...

Page 45: ...TjOH OFF High High Low High X Y Z phase OC OFF High High High Low SC OFF High High High Low UV OFF High High High Low TjOH OFF High High High Low Y phase TjW High High High High Low B phase OC OFF OFF...

Page 46: ...3 3 shows an example of P629 6in1 without alarm functions on the upper arms Figure 3 4 shows an example of P630 6in1 and Figure 3 5 shows an example of P630 7in1 Fuji Electric Co Ltd All rights reserv...

Page 47: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 3 10 Fig 3 4 IPM block diagram example P630 6in1...

Page 48: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 3 11 Fig 3 5 IPM block diagram example P630 7in1...

Page 49: ...signal is output about 20 s after VCC drops below VUV While Vin is OFF the IGBT is kept in the OFF state 3 UV protection operation continues during the tALM UV period if VCC returns to VUV VH before t...

Page 50: ...ontinues operating after that When Vin is in OFF normal operation is resumed 7 During VCC shut off the alarm signal is output when VCC drops below VUV 8 Even if the protection operating duration is su...

Page 51: ...e inclination of VCC is slow In Case 1 VCC exceeds VUV VH and Vin becomes OFF state before tALM UV elapses thus the protection operation is stopped after the elapse of tALM UV In Case 2 the protection...

Page 52: ...eration 5 2 2 During Shutdown When VCC falls below VUV an alarm signal is output after the elapse of 20 s in both Case 3 when the inclination of VCC is fast and Case 4 when the inclination of VCC is s...

Page 53: ...m signal outputs are a common output on the lower arm Therefore there are some cases when several alarm are output because of the variation in the under voltage protection level of the control ICs If...

Page 54: ...in is in OFF state before the elapse of tdOC after IC exceeds IOC the protection operation is not activated and the IGBT is turned off normally 2 4 Even if IC exceeds IOC when Vin is in ON state if Vi...

Page 55: ...comes OFF state Even if the protection operating duration is sufficiently longer than tALM OC the alarm signal is output only once 4 If a load short circuit occurs after IC began to flow the peak curr...

Page 56: ...te after the elapse of tALM TjOH 2 The protection operation continues if Vin is in ON state even if Tvj drops below TjOH TjH after the elapse of tALM TjOH 3 The protection operation continues after th...

Page 57: ...s TjOH the TjOH detection timer of which duration is approximately 1ms is reset 3 Vin Input signal voltage VALM Alarm signal voltage IC Collector current tALM TjOH Alarm signal hold time TjOH IGBT chi...

Page 58: ...d because the protection operation of tALM TjOH continues 2 The protection operation is reset after the elapse of tALM TjOH if Vin is in OFF state and Tvj drops below TjOH TjH 3 1 Soft turn off This m...

Page 59: ...VCC drops below VUV continuously for 20 s UV protection is activated and the alarm signal is output 6 The protection operation is stopped after the elapse of tALM UV if Vin is in OFF state and VCC ex...

Page 60: ...ng operation continues 1 When Tvj falls below TjW the Tvj warning signal output terminal voltage returns to VCC 2 Next if Tvj exceeds TjOH in the state of 1 an alarm signal is output and the switching...

Page 61: ...15962a 1 Typical application circuits 4 2 2 Important remarks 4 6 3 Optocoupler peripheral circuits 4 9 4 Connector 4 10 Chapter 4 Typical application circuits Fuji Electric Co Ltd All rights reserved...

Page 62: ...ights reserved Figure 4 1 shows the typical application circuits of P629 and P639 6in1 only lower arm has alarm signal output function This chapter describes the typical application circuits of the X...

Page 63: ...Ltd All rights reserved Figure 4 2 shows the typical application circuits of P626 and P636 6in1 4 3 Fig 4 2 Typical application circuits of P626 and P638 b When not using the upper arms alarm a When...

Page 64: ...l application circuits of P626 P630 P631 P636 and P638 6in1 with temperature warning function b When not using the upper arms alarm a When using the upper arms alarm If the temperature warning functio...

Page 65: ...ed Figure 4 4 shows the typical application circuits of P630 P631 P636 and P644 7in1 with built in brake 4 5 Fig 4 4 Typical application circuits of P630 P631 P636 and P644 7in1 b When not using the u...

Page 66: ...ulation between four power supply units input portion connector and PCB The four power supply units and the main power source have to be insulated from each other Be sure to secure a sufficient insula...

Page 67: ...to VCC UV protection is activated and IPM cannot be operate 2 8 Connection when there is an unused phase If there are cases when a 6in1 without brake part is used in only single phase or a 7in1 with...

Page 68: ...noise from flowing in the system 2 12 Input circuit of IPM There are constant current circuits in the input circuit of IPMs as shown in Figure 4 5 a The constant current of lin 0 15 mA or lin 0 65 mA...

Page 69: ...not guaranteed by Fuji Electric 4 9 3 1 2 Primary side current limiting resistor The current limiting resistor on the primary side should be selected so that sufficient current can flow on the second...

Page 70: ...tors are unnecessary If a large current Iout 10mA is required for the optocoupler output side it is necessary to increase the optocoupler s CTR value in order to supply the required current 3 2 3 Wiri...

Page 71: ...MT6M15962a 1 Guidelines for heat sink selection 5 2 2 Notice for heat sink selection 5 2 3 Mounting instruction of the IPM 5 3 Chapter 5 Cooling Design Fuji Electric Co Ltd All rights reserved 5 1...

Page 72: ...n please refer to the following documents Fig 5 1 Flatness of heat sink surface This chapter describes the cooling design of the X series IPM 5 2 2 Notice for heat sink selection IGBT Module Applicati...

Page 73: ...e thickness is larger than the appropriate thickness the grease layer prevents the heat transfer from the IPM to the heat sink and the junction temperature will be increased On the other hand if the t...

Page 74: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 5 4 Fig 5 2 Outline of a thermal grease application method Guide pins for IGBT Guide pins for Frame Guide holes for bottom tool...

Page 75: ...ed thermal grease thickness after spreading of thermal grease is 100 m Also please note that the optimum thermal grease thickness varies depending on the characteristics of the thermal grease used and...

Page 76: ...ive the case may be damaged 3 4 IPM mounting direction When an IPM is mounted on an extruded heat sink it is recommended that the IPM is mounted in parallel to the extrusion direction as shown in Figu...

Page 77: ...directly below the chip and verify the chip junction temperature Tvj Figure 5 4 shows an example of how to accurately measure the case temperature Tc Please measure the case temperature directly below...

Page 78: ...15962a 1 Main power supply 6 2 2 Control power supply 6 3 3 Protection functions 6 5 4 Power cycling capability 6 7 5 Others 6 7 Chapter 6 Precautions for use Fuji Electric Co Ltd All rights reserved...

Page 79: ...alfunction Connecting snubber circuits to both P1 N1 and P2 N2 is effective in suppressing surge voltage Table 6 1 Terminal arrangement of each package 1 2 Measures against exogenous noise Although me...

Page 80: ...efore action Hi OFF Lo ON 12 5 VCC 13 5 UV protection is not activated The IGBT operation follows the input signal Power dissipation tends to increase and emission noise tends to decrease Cancelled Hi...

Page 81: ...circuit should be designed to generate input signals after the alarm signal output period elapsed The alarm signal is output during shutdown of the control power supply Refer to Chapter 3 section 5 f...

Page 82: ...is output stop the input signal to the IPM and shutdown the system immediately The protection functions protect the IPM against abnormal operation but they are not able to eliminate the causes If an...

Page 83: ...29 and P639 but SC protection works and the IGBT is turned off slowly 3 2 4 Start up under short circuit or ground fault status The protection is not activated in case of the input signal pulse width...

Page 84: ...se it after fully considering the product life and usage environment If the IPM is restarted with a broken power chip the protection function will not operate properly which may result in a large scal...

Page 85: ...e is not used in a built in brake type supply the control power to the unused phases as well Supply the control power and pull up both input terminal Vin and alarm output terminal ALM to VCC If the co...

Page 86: ...MT6M15962a 1 Troubleshooting 7 2 2 Failure tree analysis charts 7 2 3 Alarm factor tree analysis chart 7 8 Chapter 7 Troubleshooting Fuji Electric Co Ltd All rights reserved 7 1...

Page 87: ...and find the root cause of the breakdown Failure tree analysis charts are shown in Figure 7 1 Carry out the investigation of the failure mode by using these charts For the failure criteria see Chapte...

Page 88: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 7 3 Fig 7 1 IPM failure tree analysis chart a Mode A Deviation from RBSOA specification b Mode B Gate overvoltage...

Page 89: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 7 4 Fig 7 1 IPM failure tree analysis chart c Mode C Excessive junction temperature rise...

Page 90: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 7 5 Fig 7 1 IPM failure tree analysis chart d Mode D FWD breakdown...

Page 91: ...MT6M15962a Fuji Electric Co Ltd All rights reserved 7 6 Fig 7 1 IPM failure tree analysis chart e Mode E Control circuit breakdown...

Page 92: ...MT6M15962a Tvj F Tc C E G E THB Fuji Electric Co Ltd All rights reserved 7 7 Fig 7 1 IPM failure tree analysis chart f Mode F Breakdown related to reliability and product handling...

Page 93: ...e factor in accordance with the alarm factor analysis tree chart indicated in Figure 7 2 Similar to V IPM it is possible to identify which protection function is activated by checking the alarm signal...

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