IRLI540NPBF N-Channel MOSFET 100V 23A Equivalent & Substitute Parts

Part Overview

The IRLI540NPBF is an N-Channel MOSFET manufactured by Infineon Technologies, rated for 100V drain-to-source voltage with 23A continuous drain current at 25°C. This device is packaged in TO-220AB Full-Pak through-hole configuration and is classified as obsolete. Due to its obsolete status, equivalent substitute parts are necessary to maintain design continuity and ensure component availability for new production and field replacements. Substitute parts must maintain electrical compatibility within the specified parameter ranges while accommodating packaging and thermal characteristics.

Substiute Parts

IRLI540NPBF

Infineon TechnologiesIn Stock: 1491IRLI540NPBF Datasheet

Current PartRFQ

FDPF3860T

onsemiIn Stock: 6443FDPF3860T Datasheet

MFR RecommendedRFQ

IRLI540G

Vishay SiliconixIn Stock: 2796IRLI540G Datasheet

MFR RecommendedRFQ

Key Parameters

Substitute Part Grouping Explanation

Substitute parts for the IRLI540NPBF are selected based on strict electrical and mechanical compatibility criteria. The primary substitution parameters are:

Electrical Compatibility Criteria:

• Drain-to-Source Voltage (Vdss): Must equal or exceed 100V
• Continuous Drain Current (Id): Must support the application current requirement
• On-State Resistance (Rds On): Lower values indicate improved performance; substitutes with comparable or lower Rds On are acceptable
• Gate Threshold Voltage (Vgs(th)): Must be compatible with drive circuitry
• Operating Temperature Range: Must encompass the application temperature envelope
• Package/Mounting: Through-hole TO-220 family packages are mechanically interchangeable

Compliance Criteria:

• RoHS Status: ROHS3 Compliant preferred for new designs
• REACH Status: REACH Unaffected acceptable
• Product Status: Active status preferred over obsolete

The IRLI540NPBF has two identified substitutes: FDPF3860T (onsemi) and IRLI540G (Vishay Siliconix). Both maintain the 100V Vdss rating and through-hole TO-220 package family, ensuring mechanical and electrical compatibility within defined parameter tolerances.

Parameter Comparison

Engineering Selection Recommendations

FDPF3860T (onsemi) - Primary Substitute:

The FDPF3860T is the recommended primary substitute for the IRLI540NPBF. This device maintains the 100V Vdss rating and through-hole TO-220 package family. The FDPF3860T delivers 20A continuous drain current, which is lower than the original 23A specification but remains suitable for applications where the design margin accommodates this reduction. The on-state resistance of 38.2 mOhm at 5.9A, 10V is superior to the original 44 mOhm specification, providing improved efficiency. The FDPF3860T is ROHS3 Compliant and carries Active product status, ensuring long-term availability and regulatory compliance for new designs. The operating temperature range extends to 150°C, which is 25°C lower than the original specification; this must be verified against application requirements. The lower power dissipation rating of 33.8W requires thermal design review for high-power applications.

IRLI540G (Vishay Siliconix) - Secondary Substitute:

The IRLI540G serves as a secondary substitute option. This device maintains the 100V Vdss rating, identical gate threshold voltage of 2V, and the full -55°C to 175°C operating temperature range of the original part. The IRLI540G delivers 17A continuous drain current, representing a further reduction from the original 23A specification. The on-state resistance of 77 mOhm at 10A, 5V is higher than the original specification, resulting in increased power dissipation and reduced efficiency. The IRLI540G is RoHS non-compliant, which restricts its use in new designs subject to RoHS regulations. This substitute is suitable only for legacy system maintenance or applications where RoHS compliance is not required. The Active product status ensures availability for field replacements.

Selection Criteria Summary:

For new designs requiring RoHS compliance and long-term availability, the FDPF3860T is the preferred substitute. For legacy systems or applications where RoHS compliance is not mandated and the full 23A current rating is not required, the IRLI540G provides an alternative with extended temperature range compatibility. Applications requiring the full 23A continuous drain current rating must evaluate whether either substitute meets the design specification or whether alternative device families must be considered.

Frequently Asked Questions (FAQ)

Q: Can the FDPF3860T directly replace the IRLI540NPBF in all applications?

A: The FDPF3860T is mechanically compatible through the TO-220 package family and electrically compatible for the 100V Vdss rating. However, the reduced continuous drain current rating of 20A versus 23A requires verification that the application current does not exceed this limit. The maximum operating temperature of 150°C versus 175°C must also be confirmed against application thermal requirements. Thermal design review is necessary due to the lower power dissipation rating of 33.8W.

Q: What are the key differences between the FDPF3860T and IRLI540G substitutes?

A: The FDPF3860T offers superior on-state resistance (38.2 mOhm versus 77 mOhm), lower gate charge (35 nC versus 64 nC), ROHS3 compliance, and a higher maximum gate voltage rating (±20V versus ±10V). The IRLI540G provides the full -55°C to 175°C operating temperature range matching the original part and a lower gate threshold voltage of 2V matching the original specification. The IRLI540G is RoHS non-compliant, limiting its use in regulated applications.

Q: Are the TO-220AB, TO-220F-3, and TO-220-3 packages mechanically interchangeable?

A: All three packages belong to the TO-220 family and share the same three-lead through-hole footprint and pin spacing. They are mechanically interchangeable on standard PCB layouts. Minor variations in tab isolation and thermal characteristics exist between variants, but these do not affect mechanical mounting or electrical connectivity for standard applications.

Q: What is the impact of the lower continuous drain current rating in substitute parts?

A: The FDPF3860T (20A) and IRLI540G (17A) have lower continuous drain current ratings than the original IRLI540NPBF (23A). Applications operating at or near the original 23A specification must be redesigned or the current requirement must be reduced to remain within the substitute device ratings. Exceeding the rated continuous drain current will result in thermal runaway and device failure.

Q: How does the on-state resistance difference affect circuit performance?

A: Lower on-state resistance reduces power dissipation and heat generation. The FDPF3860T (38.2 mOhm) provides improved efficiency compared to the original (44 mOhm), while the IRLI540G (77 mOhm) increases power dissipation. In high-current switching applications, the IRLI540G may require enhanced thermal management or circuit redesign to maintain acceptable junction temperatures.

Q: Why is RoHS compliance status important for substitute selection?

A: RoHS (Restriction of Hazardous Substances) compliance is mandatory for products sold in the European Union and increasingly required by global manufacturers. The FDPF3860T is ROHS3 Compliant, ensuring regulatory compliance for new designs and future market access. The IRLI540G is RoHS non-compliant and is restricted to legacy system maintenance or applications where RoHS regulations do not apply.

Q: What thermal considerations apply when substituting these devices?

A: The FDPF3860T has a maximum power dissipation rating of 33.8W compared to the original 54W, requiring verification that the application thermal design accommodates this lower rating. The IRLI540G rates 48W, closer to the original specification. Thermal design review including junction temperature calculations, heat sink requirements, and ambient temperature conditions is necessary for all substitutions, particularly in high-current or high-frequency switching applications.