fairchild’s 650v field stop igbt technology enables highly
TRANSCRIPT
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Fairchild’s 650V Field Stop IGBT Technology
Enables Highly Reliable System Design
Sungmo Young
Fairchild Semiconductor
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Contents
• Future of Renewable Energy and Solar Energy
• Technology and Market Outlook/Trends
• Central Inverter Topology (Central MPPT System)
• Market Requirement and Design Challenges of Solar Inverter Applications
• Fairchild’s 650V Field Stop Planar IGBT Technology, enables designers to
develop the High Reliable System design with Higher blocking voltage capability
• FSC New IGBT advantages over previous generation and competitor
• Resources:
• Landing Page for Value added Design References
• Renewable Energy Brochure
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Electricity using Renewable Energy
Source: Frost and Sullivan Report 2010
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Market Outlook: PV Inverter
• Renewable Energy - WW PV Installation Market
•The global PV inverter market is forecasted to reach $8.5billion by 2014, growing at compound
annual growth rate of nearly 25%, despite the demand adjustment in 2011(IMS).
• In the longer term, Japan’s nuclear issue will expedite demands of Renewable energy, which are led
by Solar inverter and Wind power. *10~20% of nuclear power plant development may be transferred
to renewable energy investment. (*data: Solar&Energy)
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Central Inverter Topology (Central MPPT System)
• In Central Inverter system, the Maximum
Power Point Tracking System (MPPT) converts
the DC output (typ. 150~1kV) from a string of
solar PV cells to AC (typ. over 1kW) power.
• The salient features of this topology include:
1. Single point failure can cause whole system
failures
2. Maintenance of each module is available
3. No DC wiring, Blocking Diode
4. Increasing demand of product Higher input
voltage over 600V
•The three most popular topologies
1. Boost Converter and Full-Bridge Inverter
a. Non-Isolated
b. Higher efficiency than isolated
inverter topology
2. Full-Bridge Converter and Full-Bridge
Inverter
a. Isolated PV module from grid
b. Lower efficiency than single stage
inverter
3. Boost Converter and Three-Level Inverter
a. Used for higher input voltages (700
V DC)
b. Higher efficiency than two level
inverter
c. Low cost output filter
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Technology Trends and Design Challenges of Solar
Inverter Applications
►►►► Market Trend & Requirement
• Increased demand of higher voltage rating and lower power loss (due to higher input voltage range of inverter)
• There will be increasing demand of 650V or above devices migrated from 600V IGBT & SJ MOSFET
• SiC diode and switch adoption will be accelerated more and more as the key market driver
• Major players are moving from discrete to module in order to improve the system efficiency and reliability
• Over 80% of PV inverter market will be covered by module solution within 5 years
►►►► Application details
• Key topolgy; 3 level inverter (NPC) for central system, Interleaved flyback + unfolding Inverter for micro inverter
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Component Choices for
Efficient, Cost Effective, Reliable Implementations
1. Component count
• Cost
• Size
• Total power dissipation
• Reliability
2. Heat/thermal management
• Reliability
• Size/weight
• Cost
3. Minimization of losses and parasitics
• System performance
• Total power dissipation
Regardless of which topology is used, designers must make careful choices when selecting the
individual components. The necessary improvements in performance, cost, reliability and efficiency
require special attention to the following factors and their ultimate impact on the overall system:
1. IGBTs• 650V/40A, FGA40N65SMD
• 650V/60A, FGA60N65SMD2. MOSFETs
• High-Voltage
• Mid-Voltage
3. High Voltage Gate Drivers (HVICs)
4. High-speed Low-side Gate Drivers
5. Optically Isolatated Gate Drivers
6. Bypass and Blocking Diodes
7. High Voltage Silicon Carbide [SiC]
For more solutions, please visit our website.
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Efficiency Comparison
• 3-level topologies for low voltage
applications
• Losses are distributed over
semiconductors
• Losses increase only slightly with
switching frequency
• Possible to improve inverter
efficiency and extend switching
frequency
• 3-level topologies are getting
focus in solar inverter
applications
Source: PES Lab, ETH Zurich, presented at ECPE Workshop "Advanced Multilevel Converter Systems", Västeras, Sweden, September 28-29, 2010
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Higher Blocking Voltage Capability
• DC link voltage cannot be balanced perfectly in the 3-level neutral-point-clamped
topology
• Dynamic imbalance between positive and negative parts of DC link is
inevitable even with appropriate control
• More safety margin for an application that may work under low temperature
conditions at start-up
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650V IGBT
• Breakdown voltage increase from 600V
• Important to keep switching and conduction losses same level to the 600V IGBT
• Higher blocking voltage usually results in higher Vce(sat) that leads to
performance degrading in PV inverter applications
• Vce (sat) and switching performance are in trade-off. Keeping Vce (sat) low
may increase switching loss
• Finding optimum design point in trade-off curve is critical to 650V IGBT
development
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650V IGBT Characteristics
• New 650V IGBT performance is almost identical at typical operating temperature
and current level
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0
0
30
60
90
120
150
180
Ic [
A]
Vce(sat) [V]
FGH60N60SMD, 25deg
FGA60N65SMD, 25deg
FGH60N60SMD, 125deg
FGA60N65SMD, 125deg
10 20 30 40 50 60
0.0
0.5
1.0
1.5
2.0
2.5
3.0
Ets [mJ]
Ic [A]
FGH60N60SMD, 125deg
FGA60N65SMD, 125deg
FGH60N60SMD, 25deg
FGA60N65SMD, 25deg
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Power Loss Analysis
• Estimated power loss for each switch
• Current waveforms for high freq. switches(Q1, Q3), and line freq. switches (Q2, Q4)
0.5 1.0 1.5 2.0 2.5 3.0
2
4
6
8
10
Power Dissipation, Pd [W]
Output Power, Po [kW]
FGH60N60SMD
FGA60N65SMD
High freq. switch
Line freq. switch
* Condition for calculation:
- Topology: F/B Inverter with mixed switching freq.ch with fs=17 kHz, Po=3kW
- Input DC voltage: 400V, Output voltage: 220Vac, Line freq.: 60Hz, Tc=70℃
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Power Loss Analysis
• Loss factors in detail at 3kW
10 15 20 25 30 35 40
35
40
45
Power Dissipation, Pd [W]
Switching Frequncy, fs [kHz]
FGH60N60SMD
FGA60N65SMD
FGH60N60SMD FGA60N65SMDConduction Loss [W] 4.60 4.58Turn-on Loss [W] 1.78 1.84Turn-off Loss [W] 1.35 1.41Total Pd [W] 7.73 7.83Conduction Loss [W] 7.31 7.29Freewheeling Loss [W] 3.69 3.50Total Pd [W] 11.00 10.7918.73 18.62HighFreq.LowFreq.Total Power Dissipation for a bridge [W]
at Po=3kWHigh-freq. Line-freq.
fs=17kHz
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Efficiency Test in PV Inverter
• Inverter specification
• Simulator setting for 3kW input power
MPPT Voltage Range 200 ~ 500 VDC
Norminal Input Voltage 400 VDC
Norminal Output Power 3000 W
Operating Output Voltage 220±13 VAC
Norminal Output Freq. 60±0.2 Hz
Norminal Efficiency Above 96% %
• Switching scheme, 17kHz
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Efficiency Test in PV Inverter
• CEC weighted efficiency of FGA60N65SMD
• CEC weighted efficiency of FGH60N60SMD0 500 1000 1500 2000 2500 3000
91
92
93
94
95
96
97
98
Efficiency [%]
Input Power, Pin [W]
FGH60N60SMD
FGA60N65SMDjOutput
Power[W]
PCEC,j /
Pnom
CEC
coefficient
Mesaured
Effi.Effi.CEC,j
1 300 10% 0.04 91.36 3.65
2 600 20% 0.05 95.03 4.75
3 900 30% 0.12 96.09 11.53
4 1500 50% 0.21 97.00 20.37
5 2250 75% 0.53 97.22 51.53
6 3000 100% 0.05 97.23 4.86
96.70
FGA60N65SMDCalculated CEC Efficiency
jOutput
Power[W]
PCEC,j /
Pnom
CEC
coefficient
Mesaured
Effi.Effi.CEC,j
1 300 10% 0.04 91.56 3.66
2 600 20% 0.05 95.11 4.76
3 900 30% 0.12 96.27 11.55
4 1500 50% 0.21 97.05 20.38
5 2250 75% 0.53 97.01 51.41
6 3000 100% 0.05 97.10 4.85
96.62Calculated CEC Efficiency
FGH60N60SMD
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10 15 20 25 30 35 40
40
44
48
52
Pd_total [W
]
(Total Loss for 4 switches)
Switching Frequency, fs [kHz]
FGH40N60SMD
FGA40N65SMD
best competitor
More Analysis with 40A rated IGBTs
• New 650V IGBT shows best efficiency
High-freq. Line-freq.
fs=20kHz
0.5 1.0 1.5 2.0 2.5 3.098.5
98.6
98.7
98.8
98.9
99.0
99.1
Efficiency [%]
(Only considering Pd_total)
Output Power, Po [kW]
FGH40N60SMD
FGA40N65SMD
best competitor
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Efficiency Test in PV Inverter
• CEC weighted efficiency ※※※※ CEC : California Energy Commission
91.00
92.00
93.00
94.00
95.00
96.00
97.00
98.00
300 600 900 1500 2250 3000
40N65SMD
40N60SMD
competitor A
competitor B
FGH40N60SMDFGH40N60SMDFGH40N60SMDFGH40N60SMD FGA40N65SMDFGA40N65SMDFGA40N65SMDFGA40N65SMD competitor Acompetitor Acompetitor Acompetitor A competitor Bcompetitor Bcompetitor Bcompetitor BEfficiency[%]Efficiency[%]Efficiency[%]Efficiency[%] Efficiency[%]Efficiency[%]Efficiency[%]Efficiency[%] Efficiency[%]Efficiency[%]Efficiency[%]Efficiency[%] Efficiency[%]Efficiency[%]Efficiency[%]Efficiency[%]300300300300 91.6091.6091.6091.60 92.3092.3092.3092.30 92.2992.2992.2992.29 91.5091.5091.5091.50600600600600 94.8594.8594.8594.85 94.9194.9194.9194.91 94.8294.8294.8294.82 94.8994.8994.8994.89900900900900 96.2496.2496.2496.24 96.2296.2296.2296.22 96.0296.0296.0296.02 96.1396.1396.1396.131500150015001500 96.9496.9496.9496.94 96.9596.9596.9596.95 96.9196.9196.9196.91 96.8396.8396.8396.832250225022502250 97.0097.0097.0097.00 97.1697.1697.1697.16 96.9796.9796.9796.97 96.8296.8296.8296.823000300030003000 96.7896.7896.7896.78 97.1897.1897.1897.18 97.0397.0397.0397.03 96.8296.8296.8296.82CEC CEC CEC CEC 96.5696.5696.5696.56 96.7096.7096.7096.70 96.5596.5596.5596.55 96.4396.4396.4396.43Output[W]Output[W]Output[W]Output[W]
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Conclusion
• New 650V Field Stop IGBT is developed
and its performance is evaluated in PV
inverter application.
• New IGBTs offer higher blocking voltage
capability without sacrificing performance.
System designers can have more design
margins for better system reliability.
• New IGBTs are perfect fit for PV inverter
applications and other power conversion
systems that require higher blocking
voltage.
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Visit Fairchild Web for Value Added Resources
• Please visit renewed Energy Conversion, Solar Inverter Application page to find more
solutions for your success.
• Renewable Energy Solutions Guide, Application Notes, Whitepapers are available:
• http://www.fairchildsemi.com/applications/solar-inverter/index.html
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Thank you for attending!
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