Fairchild’s 650V Field Stop IGBT Technology Enables Highly

www.fairchildsemi.com1

Fairchild’s 650V Field Stop IGBT Technology

Enables Highly Reliable System Design

Sungmo Young

Fairchild Semiconductor


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


Electricity using Renewable Energy

Source: Frost and Sullivan Report 2010


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)


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


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


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.

http://www.fairchildsemi.com/


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


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


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


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


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℃


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


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



• 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


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



• 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]


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.


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


Thank you for attending!


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Fairchild’s 650V Field Stop IGBT Technology Enables Highly