Inverter Welder

APPLIED POWER SYSTEMS, INC.
IAP300T120 SixPac
300A/1200V 3-phase Bridge IGBT Inverter
IAP300T120 SixPac FEATURES INCLUDE

Multi-Function Power Assembly Compact Size 9.00 H X 11.00 W X 17.56 D DC Bus Voltages to 800VDC Snubber-less operation to 650VDC Switching frequencies to over 20kHz Protective circuitry with fail-safe opto-isolated fault annunciation, including: OverCurrent Short circuit OverVoltage P.S. UnderVoltage OverTemperature Opto-isolated or fiber-optic gate drive and fault signal output for electrical isolation and noise immunity Integrated cooling with temperature sensors and feedback Many options - Available with IGBTs from 75A to 1200A
The IAP300T120 SixPac provides built in protection features including: OverVoltage, UnderVoltage lockout, OverCurrent, OverTemperature, short circuit and optional airflow or liquid flow indicators.
Shown with AC-DC Converter

Configurable Power
The IAP-150T120 SixPac is a flexible, highly integrated IGBT based power assembly with a wide range of applications. These include inverters for motor controls, switch mode power supplies (SMPS), UPS, welders, etc. can be operated at The IAP300T120 SixPac frequencies to over 20kHz. The IAP300T120 SixPac is configured as a three-phase bridge inverter mounted on an air-cooled or liquid-cooled heat sink. Configurations include options for (full, half or no control) converter input circuitry, inverter output circuitry, cooling and a wide variety of drivers and safety features for the converter front end and IGBT inverter output stage. To operate at high switching frequencies, the utilizes a low inductance IAP300T120 SixPac laminated bus structure, optically isolated or fiber optically coupled gate drive interfaces, isolated gate power supplies and a DC-link capacitor bank.
Flexibility is a key feature of the IAP300T120 SixPac . Options include: a choice of converter front ends, rectifier, half or full SCR control, with or without SCR gate firing boards and soft-start circuitry. A choice of cooling methods, forced air or liquid is also available. Customer provided PWM is optically coupled or a fiber optic link can be provided to the IGBT interface. Current feedback is provided by Hall effect current transducers.
The IAP300T120 SixPac is rated to maximum input voltages up to 800 VDC, switching frequencies to over 20kHz, includes many safety features to protect the IGBTs and output circuitry and can be configured to meet your application.
Schematic:
124 Charlotte Avenue Hicksville, NY 11801 Ph: 516.935.2230 Fax: 516.935.2603 Website: www.appliedps.com
Page 1 of 6 Rev.120706-01
IAP300T120 SixPac
SixPac IAP300T120
Absolute Maximum Ratings TJ=25C unless otherwise specified General IGBT Junction Temperature Storage Temperature Operating Temperature Voltage applied to DC terminals Isolation voltage, AC 1 minute, 60Hz sinusoidal IGBT Inverter Collector Current (TC=25C) Peak Collector Current (TJ<150C) Emitter Current Peak Emitter Current Maximum Collector Dissipation (TJ<150C) Gate Drive Board Unregulated +24V Power Supply Regulated +15V Power Supply PWM Signal Input Voltage Fault Output Supply Voltage Fault Output Current Symbol TJ TSTG TOP VCC VISO IC ICM IE IEM PCD Value -40 to +150 -40 to +125 -25 to +85 800 2500 300 600 300 600 890 30 18 20 30 50 Units C C C Volts Volts Amperes Amperes Amperes Amperes Watts Volts Volts Volts Volts mA
IGBT Inverter Electrical Characteristics, TJ=25C unless otherwise specified

Parameter Collector Cutoff Current Collector-Emitter Saturation Voltage Emitter-Collector Voltage Inductive Load Switching Times Diode Reverse Recovery Time Diode Reverse Recovery Charge DC Link Capacitance Symbol ICES VCE(sat) VEC td(on) tr td(off) tr Trr Qrr Test Conditions VCE=VCES, VGE=0V IC=300A, TJ=25C IC=300A, TJ=125C IE=300A VCC=600V IC=300A VGE=15V RG=1.0 Min Typ 1.8 1.9 12.2 4950 Max 1 2.4 3.2 300 80 500 300 250 Units mA Volts Volts Volts s s s s s C F
Thermal and Mechanical Parameters

Parameter IGBT Thermal Resistance, Junction to Case FWD Thermal Resistance, Junction to Case Heatsink Thermal Resistance Mounting Torque, AC terminals Mounting Torque, DC terminals Mounting Torque, case mounting Weight Symbol R(j-c) R(j-c) R(s-a) Test Conditions Per IGBT module Per FWD module 1500 LFM airflow Min Typ 0.05 .045 75 130 130 21 Max 0.13 0.18 90 150 150 Units
C/W C/W C/W

In-lb In-lb In-lb lb
Page 2 of 6 Rev.120706-01

Gate Drive Board Electrical Characteristics Parameter Unregulated +24V Power Supply Regulated +15V Power Supply PWM Input On Threshold PWM Input Off Threshold Output OverCurrent Trip OverTemperature Trip OverVoltage Trip DC Link Voltage Feedback Heatsink Temperature Feedback Output Current Feedback
IAP300T120 SixPac
Min Typ Max 20 24 30 14.4 15 18 12 15 0 2 450 98 100 102 900 See Figure Below See Figure Below See Figure Below
Units Volts Volts Volts Volts Amperes C Volts Volts Volts Volts
DC Link Feedback 1000 DC Link Voltage (Volts) 800 700 600 500 400 300 200 100 0 0 1 2 3 4 5 6 7 8 9 10 Feedback Voltage (Volts)
Heatsink Temperature (C) 120 110 100 90 80 70 60 50 40 30 20 10 0 0 1
Heatsink Temperature Feedback
900
10
Feedback Voltage (Volts)
Output Current Feedback

450 400 350 300 250 200 150 100 50 0 -50 -100 -150 -200 -250 -300 -350 -400 -450 -6 -5 -4 -3 -2 -1 0 1 2 3 4 5 6 Feedback Voltage (Volts)
Page 3 of 6 Rev.120706-01
Output Current (Amps)

Performance Curves
IAP300T120 SixPac
300 Amp Three Phase

120 110
100
Heatsink Temp
90 80 70 60 50 40 50 60 70 80 90 100 110 120 130 140 150
10KHz
5KHz
1KHz
OVT
RMS Output Current
Conditions Ambient Temperature DC Bus Voltage Load Power Factor IGBT Saturation Voltage IGBT Switching Loss Airflow Switching Conditions
Symbol TA VCC COS VCE(sat) ESW -
Value 40 600 0.8 Typical @ TJ=125C Typical @ TJ=125C 1500 3-phase PWM, 60Hz sinusoidal output
Units C Volts Volts mJ LFM
Page 4 of 6 Rev.120706-01
APPLIED POWER SYSTEMS, INC. Interface

Pin # 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 Signal Name Shield PWM APhase A Error1 PWM A+ PWM BPhase B Error1 PWM B+ PWM CPhase C Error1 PWM C+ OverTemp1 Not Connected DC Link Voltage 24VDC Input Power2 24VDC Input Power2 15VDC Input Power2 15VDC Input Power2 GND GND Heatsink Temperature GND3 IOUT Phase A GND3 IOUT Phase B GND3 IOUT Phase C NOTES: 1. 2. 3.
IAP300T120 SixPac
Description Connected to circuit ground 0-15V signal controlling the duty cycle of A- IGBT Open collector output, external pull-up resistor required. LOW=No Error; Floating=Phase A overcurrent or short circuit 0-15V signal controlling the duty cycle of A+ IGBT 0-15V signal controlling the duty cycle of B- IGBT Open collector output, external pull-up resistor required. LOW=No Error; Floating=Phase B overcurrent or short circuit 0-15V signal controlling the duty cycle of B+ IGBT 0-15V signal controlling the duty cycle of C- IGBT Open collector output, external pull-up resistor required. LOW=No Error; Floating=Phase C overcurrent or short circuit 0-15V signal controlling the duty cycle of C+ IGBT Open collector output, external pull-up resistor required. LOW=No Error; Floating=Heatsink overtemp Analog voltage representation of DC link voltage 20-30VDC input voltage range 20-30VDC input voltage range 14.4-18VDC input voltage range 14.4-18VDC input voltage range Ground reference for 15 and 24VDC inputs Ground reference for 15 and 24VDC inputs Analog voltage representation of heatsink temperature Tied to pins 18 and 19 Analog voltage representation of phase A output current Tied to pins 18 and 19 Analog voltage representation of phase B output current Tied to pins 18 and 19 Analog voltage representation of phase C output current
Open collectors can be pulled up to 30VDC Max and sink 50mA continuous. DO NOT connect a 15VDC and 24VDC source to the unit at the same time. Use one or the other. GND signals to be used for analog feedback signals, i.e. twisted pair with IOUT Phase A.
Gate Drive Interface Connector

Description Gate Drive Interface Header Recommending Mating Socket Recommended Strain Relief Symbol J1 Type 0.100 x 0.100 latching header, 26 pin 0.100 x 0.100 IDC socket, 26 pin Plastic strain relief Manufacturer 3M #3429-6002 or equivalent 3M #3399-7600 or equivalent 3M #3448-3026 or equivalent
Page 5 of 6 Rev.120706-01
APPLIED POWER SYSTEMS, INC. Mechanical Information
IAP300T120 SixPac
Page 6 of 6 Rev.120706-01

Inverter Welder

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APPLIED POWER SYSTEMS, INC.

IAP300T120 SixPac FEATURES INCLUDE

Shown with AC-DC Converter

APPLIED POWER SYSTEMS, INC.

IGBT Inverter Electrical Characteristics, TJ=25C unless otherwise specified

Thermal and Mechanical Parameters

C/W C/W C/W

APPLIED POWER SYSTEMS, INC.

Heatsink Temperature Feedback

Feedback Voltage (Volts)

Output Current Feedback

Output Current (Amps)

APPLIED POWER SYSTEMS, INC.

300 Amp Three Phase

90 80 70 60 50 40 50 60 70 80 90 100 110 120 130 140 150

RMS Output Current

Symbol TA VCC COS VCE(sat) ESW -

Units C Volts Volts mJ LFM

APPLIED POWER SYSTEMS, INC. Interface

Gate Drive Interface Connector

APPLIED POWER SYSTEMS, INC. Mechanical Information

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