ABB IEPAS02 power module

ABB IEPAS02 power module

Product positioning and core values

In industrial power electronics systems, the IEPAS02 power module plays a key role as the "energy conversion core". Its core value lies in converting input electrical energy (AC or DC) into the required form of electrical energy for the load according to control instructions, while ensuring the efficiency and safety of the conversion process. Specific positioning can be carried out from three levels:

1. Accurate conversion of electrical energy forms: As the core unit of power conversion, it can achieve bidirectional conversion (rectification or inversion) between AC and DC, as well as voltage and frequency regulation, to meet the specific needs of different industrial loads (such as motors and precision instruments) for electrical energy forms. For example, it can rectify three-phase AC power into stable DC power and supply it to frequency converters, or convert DC power into adjustable frequency and voltage AC power through inversion to drive motors.

2. Efficient and energy-saving power transmission: Advanced IGBT (Insulated Gate Bipolar Transistor) or SiC (Silicon Carbide) power devices are used, combined with optimized circuit topology design, to significantly reduce switching and conduction losses during the energy conversion process. The power conversion efficiency can reach over 98%, effectively reducing energy waste and meeting the development needs of industrial energy conservation and consumption reduction.

3. Security guarantee for system operation: Integrating multiple protection mechanisms, real-time monitoring of module working status (such as current, voltage, temperature), when there are abnormal situations such as overload, overcurrent, overvoltage, overtemperature, short circuit, etc., it can quickly trigger protection actions, cut off power output or limit output current, avoid module and backend equipment damage, and ensure the safe and stable operation of the entire power electronic system.

Core functional features

The IEPAS02 power module integrates ABB's profound technical accumulation in the field of power electronics and is optimized for the demanding requirements of industrial scenarios. It has the following outstanding functional features:

-High power density and compact design: Adopting flat power device packaging and integrated circuit design, high power output can be achieved within a limited volume, with a power density of over 5kW/L, effectively saving installation space inside the control cabinet and adapting to the compact layout requirements of small and medium-sized industrial equipment; The module adopts standardized installation interfaces for quick integration and replacement.

-Wide voltage and wide load adaptation: Supports a wide range of input voltages (such as three-phase AC 380V~480V or DC 500V~750V, depending on the model), and can adapt to industrial power grid environments in different regions; Simultaneously possessing good load adaptability, it can stably drive inductive loads, capacitive loads, and nonlinear loads, with low load adjustment rate and small output voltage/current fluctuations.

-Advanced heat dissipation and management: using efficient heat dissipation substrates and distributed heat dissipation structures, combined with low loss power devices, effectively reducing module operating temperature; Some models are equipped with intelligent temperature control fans, which can automatically adjust the fan speed according to the module temperature, ensuring heat dissipation effect, reducing fan operating noise and energy consumption, and adapting to different cooling needs under different working conditions.

-Complete monitoring and diagnostic functions: built-in high-precision sampling circuit and signal processing unit, real-time acquisition of key parameters such as input and output current, voltage, module temperature, etc; Support uploading operational data and fault information to controllers or monitoring systems through industrial buses such as CANopen and PROFINET. At the same time, the LED indicator lights on the module surface visually display the working status and fault type, making it easy to quickly troubleshoot problems.

-Industrial grade reliability and anti-interference: High grade power semiconductor devices and industrial grade capacitors, resistors, and other components are used. After strict environmental adaptability testing, the working temperature range covers -20 ℃~65 ℃, and the humidity adaptability range is 5%~95% (no condensation); The module adopts EMC optimized design internally, which can effectively resist electromagnetic interference in industrial sites and meet electromagnetic compatibility standards such as IEC 61800-3.

Key technical parameters

Module Model

ABB IEPAS02

ABB official unique model identification, used for selection and procurement

power level

5.5kW~15kW (depending on specific sub models)

Adapt industrial equipment with different power requirements

input voltage

Three phase AC 380V~480V (50/60Hz) or DC 500V~750V

Wide voltage input, suitable for AC and DC power supply scenarios

output voltage

0~Input voltage effective value (adjustable)

Support continuous voltage regulation to meet different load requirements

Rated output current

10A~30A (depending on power level)

Maximum safe current for continuous output

Peak output current

1.5~2 times the rated current (duration ≤ 1s)

Dealing with instantaneous current demand during sudden load changes

Power device type

IGBT (or SiC, depending on the sub model)

High switching frequency, low loss, suitable for high-frequency power conversion

switching frequency

2kHz~15kHz (configurable through software)

Balance conversion efficiency and output waveform quality

conversion efficiency

≥ 98% (under rated load)

Efficient and energy-saving, reducing operating costs

Operating Temperature

-20℃~65℃

Adapt to high and low temperature industrial environments

Protection level

IP20 (module body)

Suitable for installation inside control cabinets to prevent solid foreign objects from entering

communication interface

Supports CANopen and PROFINET

Realize high-speed data exchange with the control system

Applicable industries and typical application scenarios

The IEPAS02 power module is widely used in various industrial power electronics systems due to its high power density, high efficiency, energy saving, reliability, and stability. Its core applicable industries and scenarios are as follows:

1. Intelligent manufacturing industry: In industrial robot servo systems, as the power drive core, DC power is converted into adjustable frequency and voltage AC power to drive robot joint motors. Its high-precision current control capability ensures the smoothness and accuracy of robot motion; In CNC machine tools, power support is provided for servo spindles and feed systems to ensure high-speed and high-precision machining processes.

2. Energy management industry: In photovoltaic inverters and energy storage systems, it is used to achieve the conversion of direct current and alternating current, invert the direct current generated by photovoltaic modules into alternating current and integrate it into the power grid, or precisely control the charging and discharging process of energy storage batteries. Its high conversion efficiency can improve the utilization rate of photovoltaic energy; In UPS uninterruptible power supply, as the core of the inverter unit, it ensures quick switching to the backup power output in case of mains power interruption, ensuring stable load power supply.

3. Rail Transit Industry: In the auxiliary power supply system of urban rail transit, it is used to convert the high voltage electricity of the train traction power grid into low voltage direct current electricity, which supplies power to auxiliary equipment such as lighting, air conditioning, and control systems of the train; In the braking energy recovery system of rail vehicles, feedback and conversion of electrical energy are achieved to improve energy utilization efficiency.

4. Chemical and metallurgical industries: In the frequency conversion control system of fans and pumps in chemical production, as a power conversion unit, the motor speed is adjusted to match the production process requirements and achieve energy-saving operation; In the transmission system of steel rolling mills in the metallurgical industry, stable power output is provided to ensure constant motor speed during the rolling process and improve the quality of steel processing.

5. Medical equipment industry: In the power supply system of large medical equipment such as MRI and CT scanners, it is used to achieve precise conversion and stable output of electrical energy. Its low ripple and high stability characteristics can ensure the imaging quality and operational safety of medical equipment; Ensure that the backup power supply of medical emergency equipment (such as ventilators) continues to operate stably in case of sudden power outages.

Precautions for use

To ensure the long-term stable operation of the IEPAS02 power module and the entire power electronic system, the following specifications must be strictly followed during installation, wiring, debugging, and maintenance:

-Installation environment specifications: The module should be installed in a well ventilated, dust-free, non corrosive gas free, and non flammable and explosive material control cabinet, avoiding direct sunlight and rainwater erosion; The control cabinet needs to be equipped with a cooling fan or air conditioner to ensure that the ambient temperature is controlled between -20 ℃~65 ℃ and the relative humidity does not exceed 95% (without condensation); The installation distance between the module and other heating devices (such as resistors and transformers) should not be less than 30cm to ensure smooth heat dissipation channels.

-Electrical connection specifications: Before wiring, the main power supply of the system must be cut off, and a multimeter must be used to confirm that there is no residual voltage at the input and output terminals to avoid electric shock or module damage; The input and output cables should be copper core cables that meet the power level, with wire diameter specifications referring to the product manual (such as 2.5mm ² cables for 10A modules), and equipped with appropriate circuit breakers and fuses; Power cables and control cables need to be laid separately to avoid parallel wiring. It is recommended to use shielded wires and reliable grounding for control cables to reduce electromagnetic interference; The wiring terminals need to be tightened firmly to prevent poor contact from causing heating and burning.

-Debugging configuration specifications: Before debugging, it is necessary to confirm that the module model matches the load power and input power, and check whether the wiring is correct and error free; Configure module parameters through ABB dedicated debugging software or controller, including input power type, rated power, switching frequency, protection threshold, communication protocol, etc; During the initial debugging stage, a no-load test should be conducted to observe the output waveform, temperature, and current changes of the module. After confirming that there are no abnormalities, the load should be gradually increased to the rated value. It is strictly prohibited to start debugging directly with load.

-Daily maintenance points: Regularly check the status of the LED indicator lights on the surface of the module every week, and determine whether the module is working properly through the indicator lights (such as power lights, running lights, fault lights); Clean the dust on the module cooling fan and heat sink every month to avoid dust accumulation and poor heat dissipation; Check the fastening condition of the wiring terminals and the insulation layer status of the cables once a quarter, and promptly deal with any looseness or damage found; Regularly monitor the operating parameters of the module (such as temperature, current, voltage) through the monitoring system and analyze whether there are any abnormal trends.

-Fault handling specifications: When a module malfunctions and alarms, the input power should be immediately cut off. The fault code should be read through the fault indicator light or debugging software, and the cause of the fault should be checked by referring to the product manual (such as checking whether the load is short circuited for overcurrent faults, and checking the cooling system for overheating faults); It is strictly prohibited to forcefully start the module without troubleshooting; When replacing a module, it is necessary to ensure that the model, power level, and firmware version of the new module are consistent with the original module. After replacement, parameter configuration and no-load testing need to be carried out again.