TENTATIVE
PP100B120
Powerex, Inc., 200 Hillis Street, Youngwood, Pennsylvania 15697-1800 (724) 925-7272
POW-R-PAK
TM
100A / 1200V
H-Bridge IGBT Assembly
PP100B120(-)
- 1 -
Description:
The Powerex POW-R-PAK
TM
is a configurable IGBT
based power assembly that may be used as a
converter, chopper, half or full bridge, or three phase
inverter for motor control, power supply, UPS or other
power conversion applications.
The power assembly is mounted on a forced air-
cooled heatsink and features state-of-the-art Powerex
F-series trench gate IGBTs with low conduction and
switching losses for high efficiency operation. The
POW-R-PAK
TM
includes a low inductance laminated
bus structure, optically isolated gate drive interfaces,
isolated gate drive power supplies, and a DC-link
capacitor bank. The control board provides a
simple user interface along with built-in
protection features including overvoltage,
undervoltage lockout, overcurrent,
overtemperature, and short circuit detection.
Depending on application characteristics the
POW-R-PAK
TM
is suitable for operation with DC
bus voltages up to 800VDC and switching
frequencies above 20kHz.
Schematic
Features:
High performance IGBT inverter bridge
Integrated gate drive with fault monitoring
& protection
System status / troubleshooting LEDs to
verify or monitor proper operation
Isolated gate drive power supplies
Low inductance laminated bus
Output current measurement & feedback
Superior short circuit detection & shoot
through prevention
TENTATIVE
PP100B120
Powerex, Inc., 200 Hillis Street, Youngwood, Pennsylvania 15697-1800 (724) 925-7272
POW-R-PAK
TM
100A / 1200V
H-Bridge IGBT Assembly
PP100B120(-)
- 2 -
Absolute Maximum Ratings, T
j
= 25C unless otherwise specified
General Symbol
Units
IGBT Junction Temperature
T
j
-40 to +150
C
Storage Temperature
T
stg
-40 to +125
C
Operating Temperature
T
op
-25 to +85
C
Voltage Applied to DC terminals
V
CC
800 Volts
Isolation Voltage, AC 1 minute, 60Hz sinusoidal
V
iso
2500 Volts
IGBT Inverter
Collector Current (T
C
= 25C)
I
C
100 Amperes
Peak Collector Current (T
j
< 150C)
I
CM
200 Amperes
Emitter Current
I
E
100 Amperes
Peak Emitter Current
I
EM
200 Amperes
Maximum Collector Dissipation (T
j
< 150C)
P
c
500 Watts
Gate Drive Board
Unregulated +24V Power Supply
30
Volts
Regulated +15V Power Supply
18
Volts
PWM Signal Input Voltage
20
Volts
Fault Output Supply Voltage
30
Volts
Fault Output Current
50
mA
IGBT Inverter Electrical Characteristics, T
j
= 25C unless otherwise specified
Characteristics Symbol
Test
Conditions
Min
Typ
Max
Units
Collector Cutoff Current
I
CES
V
CE
= V
CES
, V
GE
= 0V
-
-
1
mA
I
C
= 100A, T
j
= 25C
-
1.8
2.4
Volts
Collector Emitter Saturation Voltage
V
CE(sat)
I
C
= 100A, T
j
= 125C
-
1.9
-
Volts
Emitter Collector Voltage
V
EC
I
E
= 100A
-
-
3.2
Volts
t
d(on)
- - 100 ns
t
r
-
-
50
ns
t
d(off)
- - 400 ns
Inductive Load Switching Times
t
f
- - 300 ns
Diode Reverse Recovery Time
t
rr
- - 150 ns
Diode Reverse Recovery Charge
Q
rr
V
CC
= 600V
I
C
= 100A
V
GE
= 15V
R
G
= 3.1
- 4.1 - C
DC Link Capacitance
3300
F
TENTATIVE
PP100B120
Powerex, Inc., 200 Hillis Street, Youngwood, Pennsylvania 15697-1800 (724) 925-7272
POW-R-PAK
TM
100A / 1200V
H-Bridge IGBT Assembly
PP100B120(-)
- 3 -
Gate Drive Board Electrical Characteristics
Characteristics
Min
Typ
Max
Units
Unregulated +24V Power Supply
20
24
30
Volts
Regulated +15V Power Supply
14.4
15
18
Volts
PWM Input On Threshold
12
15
Volts
PWM Input Off Threshold
0
2
Volts
Output Overcurrent Trip
150
Amperes
Overtemperature Trip
96
98
100
C
Overvoltage Trip
920
Volts
DC Link Voltage Feedback
See Figure Below
Volts
Heatsink Temperature Feedback
See Figure Below
Volts
Output Current Feedback
See Figure Below
Volts
Thermal and Mechanical Characteristics
Characteristics Symbol
Test
Conditions
Min
Typ
Max
Units
IGBT Thermal Resistance, Junction to Case
R
th(j-c)
Q
Per IGBT module
-
0.15
0.25
C/W
FWD Thermal Resistance, Junction to Case
R
th(j-c)
D
Per FWD module
0.35
C/W
Contact Thermal Resistance
R
th(c-f)
-
0.045
-
C/W
Heatsink Thermal Resistance
R
th(f-a)
1500 LFM airflow
0.040
C/W
Mounting Torque, AC terminals
75
90
in-lb
Mounting Torque, DC terminals
130
150
in-lb
Mounting Torque, Mounting plate
130
150
in-lb
Weight
21
lb
Heatsink Temperature Feedback
0
20
40
60
80
100
120
0
1
2
3
4
5
6
7
8
9
10
Feedback Voltage (Volts)
H
eatsi
n
k
T
e
m
p
er
atu
r
e
(
C
)
DC Link Feedback
0
100
200
300
400
500
600
700
800
900
1000
0
1
2
3
4
5
6
7
8
9
10
Feedback Voltage (Volts)
D
C
L
i
n
k
Vo
l
t
ag
e (V
o
l
ts
)
Output Current Feedback
0
50
100
150
200
250
0
1
2
3
4
5
6
7
8
9
10
Feedback Voltage (Volts)
O
u
t
put
Cur
r
e
nt
(
A
m
p
s
)
TENTATIVE
PP100B120
Powerex, Inc., 200 Hillis Street, Youngwood, Pennsylvania 15697-1800 (724) 925-7272
POW-R-PAK
TM
100A / 1200V
H-Bridge IGBT Assembly
PP100B120(-)
- 4 -
Gate Drive Board Interface Signal Definitions
Pin Signal
Name
Description
1
Shield
Connected to circuit ground
2
PWM A-
0-15 V signal controlling the duty cycle of A- IGBT
3
Phase A Error
1
Open collector output, external pull-up resistor required
LOW = No Error; Floating = Phase A overcurrent or short circuit
4
PWM A+
0-15 V signal controlling the duty cycle of A+ IGBT
5
PWM B-
0-15 V signal controlling the duty cycle of B- IGBT
6
Phase B Error
1
Open collector output, external pull-up resistor required
LOW = No Error; Floating = Phase B overcurrent or short circuit
7 PWM
B+
0-15 V signal controlling the duty cycle of B+ IGBT
8
9
10
11 Overtemp
1
Open collector output, external pull-up resistor required
LOW = No Error; Floating = heatsink overtemp
12 Not
Connected
13
DC Link Voltage
Analog voltage representation of DC link voltage
14
24 VDC input power
2
20 30 VDC input voltage range
15
24 VDC input power
2
20 30 VDC input voltage range
16
15 VDC input power
2
14.4 18 VDC input voltage range
17
15 VDC input power
2
14.4 18 VDC input voltage range
18
GND
Ground reference for 15 and 24 VDC inputs
19
GND
Ground reference for 15 and 24 VDC inputs
20
Heatsink Temperature
Analog voltage representation of heatsink temperature
21 GND
3
Tied to pins 18 and 19
22 I
out
Phase A
Analog voltage representation of phase A output current
23 GND
3
Tied to pins 18 and 19
24 I
out
Phase B
Analog voltage representation of phase B output current
25
26
Notes:
1. Open collectors can be pulled up to 30 V max and sink 50mA continuous.
2. Do not connect a 15 VDC and 24 VDC source to the unit at the same time, use one or the other.
3.
GND signals to be used for analog feedback signals, i.e. twisted pair with I
out
Phase A.
Gate Drive Board Interface Connector
Description Symbol
Type
Manufacturer
Gate Drive Board Interface Header
J1
0.100" x 0.100" latching header, 26 pin
3M# 3429-6002 or equivalent
Recommended Mating Socket
-
0.100" x 0.100" IDC socket, 26 pin
3M# 3399-7600 or equivalent
Recommended Strain Relief
-
Plastic strain relief
3M# 3448-3026 or equivalent
TENTATIVE
PP100B120
Powerex, Inc., 200 Hillis Street, Youngwood, Pennsylvania 15697-1800 (724) 925-7272
POW-R-PAK
TM
100A / 1200V
H-Bridge IGBT Assembly
PP100B120(-)
- 5 -
Performance Curves
Effective Output Current vs. Carrier Frequency (Typical)
Condition Symbol
Value
Units
Ambient Temperature
T
A
40 C
DC Bus Voltage
V
CC
600 Volts
Load Power Factor
cos
0.8
IGBT Saturation Voltage
V
CE(sat)
Typical @ T
J
= 125C
Volts
IGBT Switching Loss
E
SW
Typical @ T
J
= 125C
mJ
Airflow -
1500
LFM
Switching Conditions
1 phase PWM, 60Hz sinusoidal output
40
50
60
70
80
90
100
110
120
130
140
20
30
40
50
60
70
80
90
100 110 120 130 140 150
I
out
A
RMS
I
G
B
T
J
unc
t
i
on T
e
m
p
e
r
a
t
ur
e
10kHz
5kHz
1kHz
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