INDUSTRIAL WELDING POWER SUPPLY SOLUTIONS
High Speed, High Efficiency, High Reliability, High Performance
Fairchild’s broad power portfolio offers energy and cost-saving solutions to meet the diverse range of low-, mid- and
high-power welding inverter design requirements—high efficiency, high switching frequency while decreasing size
and weight. Our high-end IGBT technology offers optimum performance where low conduction and switching losses
are essential—even at high current levels. Rectifier provides low voltage drop as well as fast reverse recovery time
and softness factor. Integrated FPS™ series enables the auxiliary (aux) power design to achieve lower standby power
losses with compact size and reliability. Optically isolated gate drivers offer wide operating voltage range and high
common-mode transient immunity. In addition, high-voltage gate drivers have excellent noise immunity and low power
consumption.
Full-Bridge/Half-Bridge Topology for Single-(>20 kHz) and Three (<40 kHz)-Phase Inverters
• Excellent transformer utilization
• Reduced inductor current ripple (by doubling the switching frequency)
PFC
Inverter
Rectifier
Aux
Solutions
600/650 V Field Stop IGBTs without Anti-Parallel Diode
1-Phase: 600/650 V Field Stop
IGBTs with Anti-Parallel Diode
Welding Machine Block Diagram (Full Bridge Inverter Type)
Bridge Rectifier
AC Output
PFC (Option)
Ctrl
3-Phase: 1000/1200 V Field Stop
IGBTs with Anti-Parallel Diode
Primary Inverter
Driver
Driver
Driver
Driver
Rectifier
Welding Torch
DC-Link
Stage
DC Output
for Steel Welding
AUX Power
Secondary Inverter
Fast Reverse Recovery Diodes with
Low VF and Softness factor
800 V FPS™ Series,
Integrated Power Switches
Driver
Driver
Driver
Driver
Welding Torch
AUX Power
Output
Ctrl
Optocoupler
PWM Controllers,
800 V Power MOSFETs
AC Output
for Aluminum Welding
Two-Switch Forward Topology for Single-Phase Inverters (>20 kHz)
• Suited for sudden load-changes
• Excellent noise immunity
• No need for reset-circuit compared to forward topology
Solutions
PFC
600/650 V Field Stop IGBTs
without Anti-Parallel Diode
Inverter
1-Phase: 600/650 V Field Stop
IGBTs without Anti-Parallel Diode
Rectifier
Fast Reverse Recovery Diodes with
Low VF and Softness factor
Aux
Bridge Rectifier
PFC (Option)
Inverter
Rectifier
Driver
AC Output
Welding Torch
DC-Link
Stage
Ctrl
Driver
DC Output
for
Steel Welding
Optocoupler
AUX Power
800 V FPS™ Series,
Integrated Power Switches
PWM Controllers,
800 V Power MOSFETs
Ctrl
AUX Power
Output
fairchildsemi.com
High-Speed Field Stop IGBT Technology Optimized for High-End Welding Applications
Energy saving, high reliability, and compact design can be achieved by using Fairchild’s latest Field Stop IGBT
technology. Our solution is especially optimized for welding applications that require high-speed switching
characteristics balancing between switching and conduction losses. Fairchild’s high-speed IGBTs offer superior switching
performance characteristics that ensure improved system efficiency as well as minimizing total losses.
600 V/ 650 V Field Stop IGBT in Single-Phase Welder
Features and Benefits
Gate
• Low switching and conduction loss suitable for industrial applications
Emitter
• Positive temperature coefficient for easy parallel operation
N+
• Maximum junction temperature: TJ = 175°C
P-base
• High current capability up to 75 A
• Wide SOA (Safe Operating Area)
N-
• Higher breakdown voltage with excellent ruggedness characteristics
Additional Applications
N
• Solar inverters, UPS, SMPS, PFC and hard switching topologies
P+
Collector
Field Stop Planar Structure
IGBT EOFF vs. VCE(sat) Trade-off Characteristics
Power Loss Simulations on Welding Machine
15
E OFF 45%
10
FGH40N60SFD
FGH40N60SMD
FGA40N65SMD
5
1.6
1.8
2.0
V CE(SAT) 20%
2.2
Collector-Emitter Voltage, V CE(SAT) (V)
Total Power Loss, P D (W)
Switching Loss, E OFF / A (uJ)
FGH40N60UFD
FGH40N60UFD
FGH40N60SFD
FGH40N60SMD
FGA40N65SMD
Measurement Conditions
- Full-Bridge Inverter Topology
- Input: Single-phase 220 VAC
- Output: 160 A, 26.4 VDC
- PO = 4.3 kW, TC = 80°C
2.4
Switching Frequency, f SW (Hz)
fairchildsemi.com
1200 V Field Stop Trench IGBT in Three-Phase Welder
Features and Benefits
• Low saturation voltage: VCE(sat) = 1.8 V @ IC = 40 A
• High speed switching: Low EOFF = 27 µJ/A
• Easy parallel operation (positive temperature coefficient)
• Large SOA (100% inductive switching test @ IC X 4 times)
• Maximum junction temperature: TJ = 175°C
Additional Applications
• Welders, PFC and hard switching topologies
Field Stop Trench Structure
IGBT EOFF vs. VCE(sat) Trade-off Characteristics
Power Loss Simulations on Welding Machine
35
80
Total loss, Pd[W]
(Switching loss+Conduction loss)
Switching loss, E OFF / A[uJ]
Tc=25deg.C
30
Closest competitor
FGL40N120AND
FGH40T120SMD
25
V CE(sat) 33% down
FGH40T120SMD
FGL40N120AND
Closest competitor
70
60
Measurement Conditions
50
-
Full-Bridge Inverter Topology
Input: Three-phase 380 VAC
Output: 320 A, 33 VDC
PO = 10.5 kW, TC = 80°C
40
20
1.6
1.8
2.0
2.2
2.6
2.4
2.8
15K
20K
25K
30K
Switching frequency, Fsw[Hz]
Collector-Emitter Voltage, V CE(sat) (V)
Thermal Performance Comparison in Three-Phase 400 A Welder (Full Bridge)
Temperature Delta
High-Side Average
Low-Side Average
Heat Sink Average
FGH40T120SMD
52.0
45.4
19.1
Test condition: input; 380 VAC, 60 Hz, output;
33.0 V, 320 A, IGBT; 4 PCS/set
FGL40N120AND
51.3
43.6
21.5
Switching frequency: 20 kHz, duty; 38%,
IGBT current = 38 A, room temperature test
Closest competitor
54.3
47.2
20.7
Driver condition: RON = 14 ohm, ROFF = 7 ohm
fairchildsemi.com
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600 / 650 V Field Stop IGBT
VCES
IC
VCE(sat) Typ.
EOFF Typ.
[V]
@100°C[A]
[V]
[μJ/A]
FGH/B20N60SFD
600
20
2.2
8
TO247 /D2PAK
FGH40N60SF/SFD
600
40
2.3
8
TO247
FGH60N60SF/SFD
600
60
2.3
11
TO247
FGB40N60SM
600
40
1.9
6.5
D2PAK
FGH40N60SMD
600
40
1.9
6.5
TO247
FGH60N60SMD
600
60
1.9
7.5
TO247
FGY75N60SMD
600
75
1.9
10
Power247
FGA30N65SMD
650
30
1.9
6.5
TO3PN
FGA40N65SMD
650
40
1.9
6.5
TO3PN
FGA60N65SMD
650
60
1.9
7.5
TO3PN
BVCES
IC
VCE(sat)
EOFF Typ.
[V]
@100°C [A]
[V]
[uJ/A]
FGH40T100SMD
1000
40
1.9
27
FGH40T120SMD
1200
40
1.8
27
TO247
FGH40T120SMD_F155
1200
40
1.8
27
TO247LL*
FGH25T120SMD_F155
1200
25
1.8
27
TO247LL*
FGH15T120SMD_F155
1200
15
1.8
27
TO247LL*
Product Number
Package
1000 / 1200 V Field Stop Trench IGBT
Product Number
* TO247LL: TO247 Long Lead (20 mm)
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information, please see: www.fairchildsemi.com/legal
Lit. No. to 100053-002 © 2014 Fairchild Semiconductor. All Rights Reserved.
Package
TO247