EPCOS Application Guide. Automotive. Electronic Components for e-mobility Applications.

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1 EPCOS Application Guide Automotive Electronic Components for

2 At the core of e-mobility are electric drives in both cars and other motorized vehicles such as electric bikes or scooters. The demands on the drive electronics is raising the requirements on the electronic components, modules and systems used. Its strong technology and product portfolio makes us a competent and innovative partner for manufacturers of hybrid and electric vehicles. We enable the development of technologically superior solutions, especially with our components for use in converters and in the powertrain. We provide solutions based on EPCOS film capacitors for all applications designed to store electrical energy in the DC link circuit and for suppression of ripple voltages. Key components here are the power capacitor chips, or PCC that feature flexible dimensions and form factor as required by the respective application. We also offer a wide range of power inductors and transformers with rated powers of up to 3 kw for use in power conversion systems. As the electric motor dissipates no usable heat to warm the vehicles, EVs require supplementary heating units. Our EPCOS PTC heating elements are very well suited for this purpose and can be connected directly to the high-voltage battery. On the following pages you will find further special features that distinguish our products and solutions for use in e-mobility applications. 2

3 Contents Special features 4 Overview 6 Characteristics 7 Aluminum electrolytic capacitors 7 Ceramic transient voltage suppressors (CTVS) MLVs 7 EMC filters 7 Ferrites 8 Film capacitors (medium power) 8 Inductors 9 NTC thermistors 10 Power capacitors 11 PTC thermistors 11 Surge arresters 12 Transformers 12 Varistors 12 Important notes 14 Get in contact 15 3

4 Special Features Aluminum Electrolytic Capacitors VVCapacitors with AEC-Q200 qualification available Axial-lead and soldering star series VVHigh vibration resistance up to 45 g VVHigh ripple-current capability with low ESR at high temperatures Large size series VVDesign for on-board charger applications with high capacitance values VVHigh vibration resistance VVHigh CV Ceramic Transient Voltage Suppressors (CTVS) MLVs VVReliable ESD protection up to 25 kv for high-speed data buses VVHighly rugged on extreme thermal cycles and repetitive pulses VVAutomotive grade ratings (load-dump, jump-start) VVNickel barrier series acc. to AEC-Q200 EMC Filters VVEMC input filters for high power loads in automotive HV DC bus systems VVEMC output filters for DC/DC converters VVLarge filter bandwidth VVHigh insertion loss VVOptimized form factor for smallest volume VVStandard and customized designs Ferrites VVRecommended materials for automotive applications N49, N87, N92, N95, N97 VVCAN bus choke materials K1, K10 VVSuitability of other materials depends on transformer design VVWide range of ferrite accessories Film Capacitors (medium power) VVLong-term stability VVHigh pulse strength VVExcellent overvoltage capability VVery low inductance VVLow fire hazard due to liquid-free technology VVStandard and customized designs VVCapacitors with AEC-Q200 qualification available Inductors VVWide temperature range from 55 C to +150 C VVMiniaturized versions VVHigh mechanical strength VVSuitable for lead-free soldering profiles acc. to JEDEC J-STD 020D VVQualified acc. to AEC-Q200 4

5 NTC Thermistors Glass-encapsulated NTCs, leaded NTCs, temperature probes VVHigh measuring accuracy and long-term stability VVShort response time VVTemperature measurement up to +260 C VVHeat resistant and highly stable VVRugged design VVCompact dimensions VVOvermolded package VVCable-bound or integrated connector versions VVHumidity resistant VVCustomer-specific designs Inrush current limiters VVLong-term stability VVNo derating of steady state current necessary at 0 C and +60 C VVUsable in series connections up to 265 V RMS SMD NTCs VVQualified acc. to AEC-Q200 Power Capacitors VVPower capacitor chips (PCC) for DC-link function VVHigh temperature capability (up to +125 C) VVHigh peak and RMS current handling capability VVLong-term stability VVHigh pulse handling capability VVHigh overvoltage strength up to twice the rated voltage VVery low inductance (max. 20 nh) VVStandard and customized designs PTC Thermistors VVLimit temperature sensors VVInrush current limiters (self-protecting resistors) VVHeating elements Surge Arresters VVery high discharge current VVExcellent protection characteristics VVStable performance over useful life VVery high insulation resistance VVEN class III VVBuilt to automotive standard (ISO TS 16949) VVEHV series is UL 1449 graded Transformers VVMaterial class 40 C to +155 C VVHigh power density VVAdvanced thermal behavior VVPlatform designs qualified acc. to AEC-Q200 Varistors Leaded disk and CU varistors VVAutomotive grade ratings (load-dump, jump-start) VVStable protection level VVMinimum leakage current VVOperating temperature up to +125 C VVHigh resistance to cyclic temperature stress VVQualified acc. to AEC-Q200 5

6 Overview Battery management systems Boost converters Car and battery climatization DC/DC converters Electrical motors Lithium ion battery - cell management Motor inverters On-board chargers Wall chargers Aluminum electrolytic capacitors Axial-lead and soldering star Large size Ceramic transient voltage suppressors (CTVS) MLVs Automotive E series EMC filters EMC input filters EMC LV output filters Ferrites E, ELP cores PM, PQ cores Quader cores Ring cores RM, RM LP cores Film capacitors (medium power) MKP MKT Y2, X2 Inductors CAN-/ FlexRay bus chokes Power inductors SIMID NTC thermistors Glass-encapsulated NTCs Inrush current limiters Leaded NTCs SMD NTCs Temperature probes Power capacitors Power capacitor chips (PCC LP) PTC thermistors Heating elements Inrush current limiters SMD PTCs Surge arresters EHV series Transformers Current-sense transformers Boost chokes for 48 V Power chokes Power transformers Varistors EnergetiQ series Q14, Q20 ThermoFuse T14, T20, ETFV25 Leaded disk varistors S14, S20 Non flammable varistors SNF14 CU varistors 6 Please read Important notes on page 14.

7 Characteristics Series Technical data Features Ordering code/ type Aluminum electrolytic capacitors Axial-lead and soldering star V R V DC C R µf 48 V board net applications B41692 B41689 High vibration resistance up to 45 g Very low ESR Low thermal resistance High ripple current (29 A/ 30 khz/ +85 C) Up to h at +125 C Shelf life up to 15 years B41689/B41789 B41690/B41790 B41691/B41791 B41692/B43792 B41693/B41793 B43693/B43793 Large size B μf 450 V DC B μf 450 V DC Compact can size ( mm) Different terminal configurations available, e.g. 3 terminals (4.5 mm) Special design for high vibration resistance available B43504/B43508 Ceramic transient voltage suppressors (CTVS) MLVs Automotive E series Temperature range up to +150 C V R V DC C R 10 pf 10 µf V RMS V AC W LD 1 25 J Case sizes 0603, 0805, 1206, 1210, 1812, 2220 ESD protection up to 30 kv Low leakage current Controlled capacitance for additional EMI filtering Qualified acc. to AEC-Q200 Jump-start and load-dump capability B72500E B72510E B72520E B72530E B72540E B72590E EMC filters EMC input filters for high voltage DC bus V R I R 600 V DC 150 A DC, 350 A DC High insertion loss across large bandwidth Standard and customized designs P EMC LV output filters for DC/DC converters V R I R 12 V DC, 48 V DC 200 A DC High insertion loss across large bandwidth Standard and customized designs P Please read Important notes on page 14. 7

8 Characteristics Series Technical data Features Ordering code/ type Ferrites E cores Material N27, N30, N87, N97 A L nh ELP cores Material N49, N87, N92, N97 A L nh E and ELP cores are available in a wide variety of sizes E and ELP cores are supplied in single units E 5 E 80 ELP 14 ELP 64 PM cores Material N27, N87, N97 A L nh PQ cores Material N49, N87, N95, N97 A L nh PM cores are suitable for highpower transformers and energy storage chokes PM cores are supplied in sets PQ cores are a preferred shape for power conversion PQ cores are supplied in sets PM 50.. PM 114 PQ 20 PQ 50 Quader cores Material K1, N27, N87, N92, N97 A L nh Quader cores can be used for contact-less power transfer applications B67410 Ring cores Material K1, K10, N27, N30, N87, T35, T37, T38, T65 A L nh Ring cores are primarily used as EMC chokes for suppressing RF interference R 2.5 R 202 RM cores Material K1, M33, N30, N41, N48, N49, N87, N92, N97, T35, T38 A L nh RM cores Low-profile Film capacitors (medium power) Material A L N49, N87, N nh MKP V R V DC C R 1 nf 270 µf RM cores are ideal for low-loss/ highly stable filter coils Sizes are specified according to IEC RM cores are supplied in sets Low-profile RM cores are specified acc. to IEC Low-profile RM cores are supplied in sets High current capability Low ESR 2-pin, 4-pin and 12-pin versions available RM 4 RM 14 RM 4 LP RM 14 LP B32674 B32678 B32651 B32656 MKT V R V DC C R 1 nf 220 µf High pulse strengh High contact reliability B32520 B32529 X2 V R 305 V AC C R 47 nf 2.2 µf All necessary safety approvals ENEC, UL, CSA B32932 B32936 Y2 V R 300 V AC C R 1 nf 1 µf All necessary safety approvals ENEC, UL, CSA Use only after consultation concerning the application B32021 B Please read Important notes on page 14.

9 Characteristics Series Technical data Features Ordering code/ type Inductors CAN-/ FlexRay bus chokes L R l R 5 µh 4.7 mh up to 1.2 A Miniaturized types ACT45B, B82789 in size 1812 Bifilar and sector winding Temperatures up to +150 C For reflow soldering and gluing B82787 (ACT45B) B82789C0 B82789S0 B82793C0 B82793S0 Power inductors L R µh I R up to 11 A Case sizes mm SIMID 0603-C L R nh l R ma Case size 0603 Shielded and unshielded versions Low DC resistance Temperature up to +150 C Qualified acc. to AEC-Q200 Copper plated ceramic core Laser cut winding Epoxy coated B82462A B82462G B82464A B82464G B82464P B82472P B82473M B82475M B82477P B82496C SIMID 0805-F L R nh I R ma Case size 0805 Cubic coil with ceramic core Epoxy molded flat top for vacuum pickup Winding ends welded to the terminals B82498F SIMID 1210-H L R µh l R ma Case size 1210 Ferrite drum core Laser welded winding Flame retardant molding B82422H SIMID 1812-T/C L R µh l R ma Case size 1812 Ferrite drum core Laser welded winding Flame retardant molding B82432C B82432T SIMID 2220 L R 1 µh 10 mh l R ma Case size 2220 Ferrite drum core Laser welded winding Flame retardant molding B82442 Please read Important notes on page 14. 9

10 Characteristics Series Technical data Features Ordering code/ type NTC thermistors Glassencapsulated NTCs G1541 G1551 G1561 Temperature range C (G C) Rated resistance at +25 C kw Resistance tolerance ±1% ±3% Insulation resistance > 100 MW 500 V DC (1 s) High-temperature resistant Insulated wires with high insulation voltage Non-standard wire configurations B57541G1 B57551G1 B57561G1 Inrush current limiters S364 Rated resistance at 25 C 1 10 W up to 16 A Limiting of inrush current Taped versions for automatic processing B57***S****M V RMS 265 V UL approval (E69802) High accuracy and easy mounting Lead spacing 5 and 7.5 mm Leaded NTCs S86* S87* S88* Temperature range C Rated resistance at +25 C kw Resistance tolerance ±1% ±5% Nonstandard lead configurations Taped versions for automatic processing Lead spacing 2.5 and 5.0 mm (S87*, S88*) B5786*S B5787*S B5788*S B579**S UL approval (S86*) SMD NTCs Temperature range C Rated resistance at 25 C kw Case sizes 0402, 0603, 0805 Resistance tolerance ±1%, ±3%, ±5% Qualified acc. to AEC-Q200 Operating temperatures up to +150 C B57***V5 B-tolerance ±1% ±3% Temperature probes Outside temperature sensor Temperature range C IP6K6, IPX9K for 30 s Humidity resistant 2000 h immersion test at +80 C Thermal cycling 480 cycles with applied voltage cycles on/off Thermal shock 200 cycles in air transition time < 30 s Upon request Motor temperature sensor Battery fluid sensor Temperature range C Humidity resistant 500 h test at +40 C with 93% humidity Thermal cycling 1000 cycles without voltage Cable-based design Temperature range C Response time < 20 s in oil Thermal cycling 21 days without voltage Design allows direct detection of battery fluid Cable based design Upon request Upon request 10 Please read Important notes on page 14.

11 Characteristics Series Technical data Features Ordering code/ type NTC thermistors Screw-on battery sensor Clip-on battery sensor Power capacitors Power capacitor chips PCC LP Temperature range C Response time < 20 s in silicone oil Thermal cycling 240 h with applied voltage Humidity resistance Screw design for fast and reliable mounting Cable based design Temperature range C Thermal cycling 240 h with applied voltage V R C R V DC μf Temperature range C Short time operation max C 2 hours on/off Response time < 20 s in water Cable-based design Clip design for fast and reliable mounting at different pipe diameters Volume fill factor of nearly 1 Low inductance (max. 20 nh) Long useful life (approx h) Standard and customized designs Available in flat winding and stacked winding technology Upon request Upon request B25655J B25655M B25655P B25655W PTC thermistors Heating elements V R V Self-protecting Wide range of temperatures, resistances and sizes Rectangular elements available Customer-specific solutions available- Upon request Inrush current limiters (self-protecting resistors) R R 56 W, V link,max 620 V R R 120 W, V link,max 800 V Small size Self-protecting Customer-specific solutions available B59451C1130B070 B59412C1130B070 SMD PTCs V max 32 V Rated resistance 470 W Temperature tolerance ±5 C Case sizes 0402, 0603, 0805 Qualified according to AEC-Q200 rev. D UL approval Fast and relaiable response B59721A B59641A B59421A Please read Important notes on page

12 Characteristics Series Technical data Features Ordering code/ type Surge arresters EHV DC breakdown voltage 2500, 3000, , 4500 V Transformers Max. discharge current 8/20 µs 5 ka High discharge current and isolation resistance High voltage types available Application in series with MOV Small size Wide range of lead configurations B88069X2733 B88069X2553 B88069X3003 B88069X2563 B88069X2573 Current-sense transformers (CTEM series) EP7, EP10 I sense up to 30 A RMS Turns ratio 150 up to 1180 Voltage-time product up to 423 Vx μs Basic isolation HV Typ test 2800 V DC B78417 B78419 Boost chokes for 48 V (BCEM series) I sat L R A 3.5 up to 15 μh High rated current, low DC resistance Upon request Power chokes (PCEM series) ER51/58/62 L R 1 3 µh l R up to 210 A Basic isolation Low DC resistance B78* Power transformers (PTEM series) ER62 Power U in,typ U out,typ W V V Basic isolation Optimized cooling concept B78* Varistors ThermoFuse varistors T14 T20 ETFV25 8/20 µs 8/20 µs 8/20 µs V RMS 6 ka 10 ka 20 ka V Disk varistor and fuse in one housing Space saving Monitoring option with 3 rd lead UL approval to UL 1449 B72214T B72220T B72225T 12 Please read Important notes on page 14.

13 Characteristics Series Technical data Features Ordering code/ type Varistors EnergetiQ varistors Q14 Q20 8/20 µs 8/20 µs V RMS 8 ka 15 ka V Maximum load capacity at minimum component Height miniaturization High surge current rating up to 15 ka B72214Q B72220Q Leaded disk varistors S14 S20 8/20 µs 8/20 µs V RMS up to 6 ka up to 12 ka V High surge current ratings up to 12 ka High energy ratings (2 ms) up to 440 J For high energy absorption B72214S B72220S Non flamable varistor SNF14 8/20 µs 8/20 µs V RMS up to 6 ka up to 12 ka V High surge current ratings up to 12 ka IEC (needle flame test) B72214X B72220X Qualified according to AEC Q200 CU varistors V R V DC C R pf V RMS V AC W LD 6 12 J Case sizes 3225, 4032 Jump-start and load-dump protection acc. to ISO 7637, pulse 5 Overvoltage protection in SMT version of standard disk varistors (5 and 7 mm diameter) Qualified acc. to AEC-Q200 B72650M B72660M Display of ordering codes for EPCOS products The ordering code for one and the same EPCOS product can be represented differently in data sheets, data books, other publications, on the EPCOS website, or in order-related documents such as shipping notes, order confirmations and product labels. The varying representations of the ordering codes are due to different processes employed and do not affect the specifications of the respective products. Detailed information can be found on the Internet under Please read Important notes on page

14 Important Notes The following applies to all products named in this publication 1. Some parts of this publication contain statements about the suitability of our products for certain areas of application. These statements are based on our knowledge of typical requirements that are often placed on our products in the areas of application concerned. We nevertheless expressly point out that such statements cannot be regarded as binding statements about the suitability of our products for a particular customer application. As a rule, EPCOS is either unfamiliar with individual customer applications or less familiar with them than the customers themselves. For these reasons, it is always ultimately incumbent on the customer to check and decide whether an EPCOS product with the properties described in the product specification is suitable for use in a particular customer application. 2. We also point out that in individual cases, a malfunction of electronic components or failure before the end of their usual service life cannot be completely ruled out in the current state of the art, even if they are operated as specified. In customer applications requiring a very high level of operational safety and especially in customer applications in which the malfunction or failure of an electronic component could endanger human life or health (e.g. in accident prevention or lifesaving systems), it must therefore be ensured by means of suitable design of the customer application or other action taken by the customer (e.g. installation of protective circuitry or redundancy) that no injury or damage is sustained by third parties in the event of malfunction or failure of an electronic component. 3. The warnings, cautions and product-specific notes must be observed. 4. In order to satisfy certain technical requirements, some of the products described in this publication may contain substances subject to restrictions in certain jurisdictions (e.g. because they are classed as hazardous). Useful information on this will be found in our Material Data Sheets on the Internet ( Should you have any more detailed questions, please contact our sales offices. 5. We constantly strive to improve our products. Consequently, the products described in this publication may change from time to time. The same is true of the corresponding product specifications. Please check therefore to what extent product descriptions and specifications contained in this publication are still applicable before or when you place an order. We also reserve the right to discontinue production and delivery of products. Consequently, we cannot guarantee that all products named in this publication will always be available. The aforementioned does not apply in the case of individual agreements deviating from the foregoing for customer-specific products. 6. Unless otherwise agreed in individual contracts, all orders are subject to the current version of the General Terms of Delivery for Products and Services in the Electrical Industry published by the German Electrical and Electronics Industry Association (ZVEI). 7. The trade names EPCOS, Alu-X, CeraDiode, CeraLink, CeraPad, CeraPlas, CSMP, CSSP, CTVS, Delta- Cap, DigiSiMic, DSSP, ExoCore, FilterCap, FormFit, LeaXield, MiniBlue, MiniCell, MKD, MKK, MotorCap, PCC, PhaseCap, PhaseCube, PhaseMod, PhiCap, PQSine, SIFERRIT, SIFI, SIKOREL, SilverCap, SIM- DAD, SiMic, SIMID, SineFormer, SIOV, SIP5D, SIP5K, TFAP, ThermoFuse, WindCap are trademarks registered or pending in Europe and in other countries. Further information will be found on the Internet at 14

15 Get in Contact Europe Austria TDK Austria GesmbH T F Bulgaria, Greece, Macedonia TDK Austria GesmbH T F Czech Republic TDK Czech s.r.o. T F Finland, Estonia TDK Nordic Oy T F France, Belgium, Luxembourg, Malta TDK Electronics France SAS T F Germany, Liechtenstein, Netherlands, Switzerland TDK Europe GmbH T (D) (0.14 Euro/min.) (NL) (CH) F Hungary TDK Electronics Hungary Ltd. T F Italy TDK Italy S.r.l T F Poland, Latvia, Lithuania TDK Polska Sp. z o.o. T F Portugal TDK Electronics Spain S.L.U. T F Romania TDK Austria GesmbH T F Russia, Belarus, Kazakhstan, Moldavia, Ukraine TDK CIS LLC T Slovakia TDK Austria GesmbH T F Bosnia and Herzegovina, Croatia, Montenegro, Serbia, Slovenia TDK Austria GesmbH T F Spain TDK Electronics Spain S.L.U. T F Sweden, Iceland, Denmark, Norway TDK NORDIC AB T F Turkey TDK Europe GmbH T F United Kingdom, Ireland TDK UK Limited T F Asia Afghanistan, Iran, Iraq, Jordan, Lebanon, Pakistan, Syria TDK Europe GmbH T F China EPCOS (Shanghai) Ltd. T F Hong Kong EPCOS Limited T F India, Bahrain, Bangladesh, Kuwait, Nepal, Oman, Qatar, Saudi Arabia, Sri Lanka, United Arab Emirates EPCOS India Private Ltd. T F Israel TDK Sales Representative T Japan TDK Corporation T Korea EPCOS Korea LLC T F Malaysia EPCOS RDC SDN. BHD. T F Philippines c/o TDK Electronics Philippines Corporation T F Singapore, Indonesia, Thailand, Vietnam EPCOS Pte., Ltd. T F Taiwan EPCOS Taiwan Co. Ltd. T F Americas USA, Canada, Mexico EPCOS Inc. T F South America EPCOS do Brasil Ltda. T Ext F Australia Australia, New Zealand Electronic Component Solutions Pty Ltd T F Africa Egypt TDK Europe GmbH T F Morocco, Tunisia TDK Electronics France SAS T F South Africa TDK Sales Representative T F /15 The addresses of our worldwide distributors and regional sales offices are available at Corporate Communications, P.O.Box , Munich, Germany Reproduction, publication and dissemination of this publication and the information contained therein without EPCOS' prior express consent is prohibited.

16 EPCOS AG A TDK Group Company Edition 2015 Ordering No. EPC Printed in Germany AG

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