Power Semiconductor Assemblies, Components and Custom Solutions
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- Earl Robbins
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1 Power Semiconductor Assemblies, Components and Custom Solutions With over 80 years of experience, our dedicated team of talented design engineers can deliver a wide variety of industry leading solutions ranging from simple standard sub-assemblies to complicated multimegawatt power systems. IXYS UK s power electronics assemblies group has been an integral part of our core business since the early 1920 s when we began production of the first commercially available solid state rectifiers. Our dedicated team of highly experienced specialists are on hand to provide our customers with first class support on everything from a simple air-cooled rectifier to a highly integrated custom power converter. Using the latest 3D modelling and simulation techniques, we can significantly reduce the cycle time from concept to fully developed design, minimising risk and identifying opportunity for optimisation early in the project. With double digit growth in the preceding 5 years, in 2010 we moved into a new 300m 2 dedicated production facility complemented by a wellequipped power lab. These new facilities, supported by an expanded team of engineers and technicians form the foundations for continued investment and growth in this strategic area of our business. IUK-TSM Issue /05/2016
2 Drawing on our vast experience, product portfolio and industry contacts, our team is ready to work with you to produce complete solutions to your power electronic problems. In many cases you will know exactly what you need how it will be cooled, controlled, interfaced and implemented. However, in some cases you will have an idea, concept or problem that needs developing into a complete solution. Whatever your needs, our team of specialists, working closely with you, can provide a state of the art solution that adds real value to your business An example of this approach is this water-cooled press-pack IGBT 3- level inverter assembly developed specifically for a medium voltage wind turbine generator offering class leading power density and reliability 3-level inverter assembly Step 1 - Problem Step 2 - Design There are several subtle concepts incorporated into this design to allow extended operational life and reliability under the high thermal load cycle duty and the exceptionally harsh environments of this application Fully controlled, 850VDC, 3861A bridge rectifier Another example of a bespoke design from IXYS UK is the Step 3 - Manufacture force air-cooled three phase fully controlled bridge, 1850A 55 C, 500V RMS line to line shown below. As part of the replacement project, the assembly was tailored to fit an existing cubicle. This solution enables overload currents of up to 3430A DC for 10s Step 4 - Deliver We can develop custom heatsinks, coolers, clamps, capacitors, semiconductor fuses, control electronics and mechanical packaging optimised to your application. Add to this our in house expertise in power semiconductor technologies, both within IXYS UK and the wider IXYS organisation, nobody is better prepared and able to deliver excellence in the field of power electronics assemblies Forced air-cooled three phase fully controlled bridge excitation rectifier for power stations Among the many components which go to make up this complex assembly are IXYS UK s phase control thyristor N4400TC280, heatsinks, fans, semiconductor protection fuses, capacitors and resistors IUK-TSM Issue /05/2016
3 Standard assemblies Press-pack IGBT 3-level inverters A range of 3-level topology assemblies using press-pack IGBT technology have been developed to serve applications at the highest end of the power market. 3 separate designs are available, a totally independent 3.3kV system, a 6.6kV system and a 10kV system. The 6.6kV and 10kV systems are based on the combination of 2 IGBT stacks and 1 diode stack. Each system benefits from direct water cooling to provide highly effective heat dissipation away from the devices and pre-loaded disc spring clamping to evenly distribute the applied force across the entire surface area of the device. Also designed into each system is an integrated snubber circuit Features and benefits Direct water cooled for effective heat dissipation Pre-loaded clamping to evenly distribute the applied force Isolated clamping rod system Integrated snubber circuit Single unit mechanical configuration: Short inductance paths for relative size of unit to avoid high stray inductance Advanced optically fired gate trigger circuits 3.3kV system Complete phase leg Power Rating (MW) 8 Nominal Line Current (Amps) 1600 No. of IGBT s 4 No. of Diodes 6 No. of Coolers 13 Required IGBT Type T2400GB45E Required Diode Type E2400TC45C XA1600GV45WT IUK-TSM Issue /05/2016
4 3.3kV system forced air cooled version Where no existing water supply is present or in environments where this is not possible, IXYS UK can also supply a forced air cooled version of the 3.3kV inverter Please contact IXYS UK for more information IXYS UK can also supply 6.6kV and 10kV multi-stack solutions based on 2 IGBT stack and 1 diode stack per phase leg. These can be custom designed to suit mechanical requirements and available as either watercooled or forced air cooled. Please contact IXYS UK for more information. 6.6kV system 10kV system Power Rating (MW) 12 Nominal Line Current (Amps) 1000 No. of IGBT s 4 No. of Diodes 4 No. of Coolers 5 Power Rating (MW) 16 Nominal Line Current (Amps) 1000 No. of IGBT s 6 No. of Diodes 6 No. of Coolers 7 Required IGBT Type T1600GB45G Required IGBT Type T1600GB45G Required Diode Type E2400TC45C Required Diode Type E2400TC45C Phase leg schematic Phase leg schematic IUK-TSM Issue /05/2016
5 A standard assembly module provides the basic building block for the Westack range of assemblies Assembly modules can either incorporate single or dual devices and allow the building of: Single phase diode and thyristor bridges Three phase diode and thyristor bridges Six phase diode and thyristor bridges Custom built assembly can be provided when a standard solution is not available Cooling Each module section is provided with a low noise 115V/230V ac fan which is protected against overloading by an integral thermal cut-out Surge suppression and fusing To provide reliable and safe operation, surge suppression (protecting the devices from voltage transients) and high speed fuses (to protect against short circuit) are available. IUK-TSM Issue /05/2016
6 Figure 1 Figure 3 Figure 5 Figure 2 Figure 4 Figure 6 IUK-TSM Issue /05/2016
7 A simple, highly efficient range of stacks incorporating the WESPACK range of phase control thyristors. Currently available in 3 standard configurations; AC Voltage Regulators Single Phase Bridges Three Phase Bridges Cooling Each module section is provided with a low noise 115V/230V ac fan which is protected against overloading by an integral thermal cut-out WESPACK devices provide maximum power rating for weight and volume without compromising on quality and reliability Surge suppression and fusing can be added to protect the devices from voltage transients and short circuits Fully dimensioned drawings are available on request from the Chippenham factory Figure 1 Figure 2 Figure 3 IUK-TSM Issue /05/2016
8 Easy mount standard rectifier assemblies These new assemblies, which can be supplied either with the diodes ready mounted or as kits allow for easy mounting of rectifier diodes to cooling fins using four bolts. The diodes are single side mounted directly to a copper base plate pre-drilled with the four bolt holes. Diodes can be either anode or cathode side down, with three versions available suitable for 34mm to 50mm electrode devices. An extensive range of standard parts is available, see overleaf, with the mounting hole positions compatible with the now obsolete range of flat based rectifiers previously offered by a number of manufacturers. Applications Rail Applications Traction Main Drives DC Locomotives Trackside Substations Front-end Rectification Power Conversion Marine and Off-Shore Applications Features and Benefits Design compatible with obsolete flat based rectifiers Utilises high reliability, hermetically sealed IXYS UK capsule diodes Voltage ratings up to 4.5kV Current ratings up to 2035A Direct single side mounting to cooling plates I TAV Part No. Base Polarity V RRM T C 100 C I TSM i 2 t V T0 r T R th T JM V A ka A 2 s V mω K/W C Outline W1185LC450KBR Anode WC64 W1185LC450KBN Cathode WC64 W1411LC360KBR Anode WC64 W1411LC360KBN Cathode WC64 W1524LC300KBR Anode WC64 W1524LC300KBN Cathode WC64 WC64 W1748LC220KBR Anode WC64 W1748LC220KBN Cathode WC64 W2058LC120KBR Anode WC64 W2058LC120KBN Cathode WC64 W1185LC450KCR Anode WC65 W1185LC450KCN Cathode WC65 W1411LC360KCR Anode WC65 W1411LC360KCN Cathode WC65 W1524LC300KCR Anode WC65 W1524LC300KCN Cathode WC65 W1748LC220KCR Anode WC65 W1748LC220KCN Cathode WC65 WC65 W2058LC120KCR Anode WC65 W2058LC120KCN Cathode WC65 W3082MC450KDR Anode WC66 W3082MC450KDN Cathode WC66 W3708MC350KDR Anode WC66 W3708MC350KDN Cathode WC66 W3842MC280KDR Anode WC66 W3842MC280KDN Cathode WC66 W5636MC150KDR Anode WC66 W5636MC150KDN Cathode WC66 - Assembly supplied as kit of parts, all other designs available as either kit of parts or fully assembled WC66 IUK-TSM Issue /05/2016
9 Custom assemblies traction applications With over 40 years of experience, our dedicate team of design engineers can deliver solutions to a whole range of design problems, ranging from simple trackside rectifiers to complex propulsion converters IXYS UK power electronic assemblies group pioneered the early development of solid state converters for traction systems in the late 1950 s as part of the Westinghouse brake & signal company. Over the years we have gained an enviable reputation within the rail sector as a solution provider Using our experience and broad network of contacts within the industry, we are able to offer assistance in tackling issues such as; component obsolescence, improving power equipment reliability, contract maintenance of power modules, refurbishment of power electronics, upgrades to existing systems and, of course, subcontract manufacture for Working systematically to the highest international standards, we can give your equipment a new lease of life and help protect your investment in these valuable assets Component obsolescence is becoming a significant problem for the rail sector as equipment design life invariably exceeds that of the modern power electronics components. Our highly skilled team of engineers are able to re-engineer older equipment to incorporate the latest technology whilst maintaining compatibility An example of this is replacing obsolete force commutated thyristors in a propulsion converter with a state of the art press-pack IGBT solution 4MW, 1500VDC traction rectifier As equipment reached half-life, many of the major power components will reach the end of their useful life resulting in a sharp decline in equipment reliability and availability. In these circumstances we can offer a full overhaul and refurbishment program for your power electronics, from engineering analysis, test and measurement through to delivery and validation of refurbished equipment For larger projects such as fleet wide refits, we are able to work within a consortium of specialist international companies to ensure you have the right skills on hand to deliver turnkey solutions to your requirements. This may include system analysis, project management, risk Powering Transport from generation to locomotives, our products are hard at work around the globe providing reliable energy control IUK-TSM Issue /05/2016
10 Custom assemblies our design philosophy From concept through development and manufacture to after sales support, we believe strongly in working closely with our customer every step of the way extending our philosophy of teamwork beyond our own organisation We understand that good communication and close collaboration help us provide the very best service to our customers Using the latest 3D modelling techniques we can visualise concepts and check form, fit and function with virtual prototypes. Also, utilising advanced software packages, IXYS UK can carry out simulation modelling, allowing us to model pressure drops through coolers/manifolds and heat flows through heatsinks. Whether finding solutions to complex engineering problems or simply manufacturing to your designs, you will find IXYS UK offers outstanding value for money, excellent quality and first class customer service Design By working closely together from the very start of a project we aim to provide the best solutions on time and in budget IXYS UK s extensive range of discrete components are used Power semiconductors are at the heart of any power electronics system. Our portfolio of tried, tested and trusted power semiconductor devices and skills in applying them make us the logical choice for you power electronic traction needs 3D Modelling IXYS UK has a broad range of high power semiconductor devices available ranging from simple rectifier diodes to state of the art press-pack IGBT s; Pressure drop analysis Realisation IUK-TSM Issue /05/2016
11 Supporting components Precision bar clamps Introducing a new range of low cost, high quality bar clamps to complement the range of IXYS UK Westcode high power semiconductor capsules This range of high quality, precision clamps have a maximum force of up to 4500kgf (45kN) and is ideally suited for semiconductor devices up to 63mm electrode diameter (112mm capsule diameter)* A two-rod system is used with Belleville washers to give even clamping force on the device. The pre-calibrated indicator eliminates the need for any special tools or torque wrenches. The insulator material has been specially selected to ensure the best performance of dielectric and mechanical compressive strength and also allows for high temperature operation up to C junction temperature. Range Part Number Force Max Cell Diameter T JMAX kgf mm C XSK00500DA042Mxxx XSK042 XSK00500DT042Mxxx XSK00500DF042Mxxx XSK01500DA065Mxxx XSK065 XSK01500DT065Mxxx XSK01500DF065Mxxx XSK02200DA075Mxxx XSK075 XSK02200DT075Mxxx XSK02200DF075Mxxx XSK03000DA087Mxxx XSK087 XSK03000DT087Mxxx XSK03000DF087Mxxx XSK103 XSK112 XSK03200DA103Mxxx XSK03200DF103Mxxx XSK#####DA112Mxxx 3800/ XSK#####DF112Mxxx 3800/ For outline drawings and dimensions please see the IXYS Selector guide IUK-TSM Issue /05/2016
12 Supporting components Bar clamps for WESPACK and GTO thyristors Part No. Rod size and length Insulator size and length Fixing centres Maximum electrode diameter Clamp force range Max clamp height mm mm mm mm kn mm XSK1500DA M8 x 90 M8 x XSK1500DA M8 x 130 M8 x XSK1500DA M8 x 160 M8 x XSK2000DA M8 x 95 M8 x XSK2000DA M8 x 130 M8 x XSK2000DA M8 x 160 M8 x XSK3000DA M8 x 100 M8 x XSK3000DA M8 x 130 M8 x XSK3000DA M8 x 160 M8 x XSK3400DA M8 x 100 M8 x XSK3400DA M8 x 140 M8 x XSK3400DA M8 x 160 M8 x XSK3800DA116M076 M10 x 150 M12 x XSK3800DA116M101 M10 x 180 M12 x XSK4400DA116M076 M10 x 150 M12 x XSK4400DA116M101 M10 x 180 M12 x XSK6000DA116M076 M10 x 150 M12 x XSK6000DA116M101 M10 x 180 M12 x Box Clamps Part No. XK0450BA019M XK0450BB019M Moulded box style Injection Compression Fixing centres Bolt size Outline Capsule device Mounting surface diameter Nominal thickness mm mm mm mm Outline Ref. 50 PCD M5x50 DO-200AA/TO-200AB WC48 XK0450BA025M Injection 50 PCD M5x50 DO-200AA/TO-200AB WC49 XK0450BB025M Compression XK1500BA034M Injection 70 PCD M6x50 DO-200AB/TO-200AC WC50 For outline drawings and dimensions please see the IXYS Selector guide WC50 WC48/49 IUK-TSM Issue /05/2016
13 Standard Bar Clamps Part No. Fixing centres Bolt size Outline Capsule device Mounting surface diameter Nominal thickness mm mm mm mm C XK0450DA056M XK0450DT056M XK0450SA056M XK0550DA056M XK0550SA056M M8 M8 DO-200AA/TO-200AB GTO XK0900SA056M 65 M8 Diode/Thyristor XK0600DA074M XK0600SA074M 89 M10 Press-Pack IGBTs XK1000DA074M XK1000SA074M 89 M10 Press-Pack IGBTs XK1100DA076M 89 M10 DO-200AB/TO-200AC XK1130DA076M XK1130DT076M 89 M10 DO-200AB/TO-200AC XK1130SA076M XK1800DA076M XK1800DT076M XK1800SA076M XK2100DA076M 89 M10 Wespack PCT XK2100DA076ML M10 GTO XK2100SA076M XK2100SA076ML 125 XK2140SA076M 89 M10 D0-200/Thyristor XK2140SA076ML 125 XK2700DA076M XK2700DT076M XK2700SA076M XK2000DA114M XK2000SA114M M10 M12 Wespack PCT Press-Pack IGBTs XK2500DA114M XK2500SA114M 132 M12 Press-Pack IGBTs XK2500DA116M XK2500DA116ML M12 GTO XK2500SA116M XK2500SA116ML 125 XK3000SA116M 132 M12 D0-200AD/Thyristor XK3000SA116ML 125 XK3500DA116M XK3500DA116ML M12 GTO XK3500SA116M XK3500SA116ML 125 XK4000SA116M 132 M12 Diode/Thyristor XK4000SA116ML 125 XK5000DA128M 146 M16 GTO XK5000DA128ML 125 XK7000DA128M 146 M16 Diode/Thyristor XK7000DA128ML 125 XK3060DA140ML XK3060SA140ML 154 M12 Press-Pack IGBTs XK9000SA160M 180 M16 Thyristor XK9000SA160ML 125 XK9000DA160M 180 M16 Thyristor XK9000DA160ML 125 XK6120DA180ML XK6120SA180ML 196 M16 Press-Pack IGBTs T JM IUK-TSM Issue /05/2016
14 Heatsinks Part No. Weight Periphery Area kg mm mm 2 Figure XSFGxxxxAN WH1 XSFGAxxxxAN WH2 XSFHxxxxAN WH3 XSFTxxxxAN WH4 XSFTBxxxxAN WH5 XSFTCxxxxAN WH6 SXFLPxxxxAN WH7 SXF46xxxxAN WH8 SXF30xxxxAN Dimensions 125mm x 125mm x 4 vanes WH9 WH1 WH2 WH3 WH4 WH5 WH6 WH7 WH8 WH9 For outline drawings and dimensions please see the IXYS Selector guide IUK-TSM Issue /05/2016
15 Coolers and Cooler Accessories Part No. Weight Cooler Thickness Busbar Thickness kg mm mm Description XW076NC16A N/A 47mm WC Cu XW076NC16B 47mm WC Cu w/ Busbar (10mm Hose) XW076NC16BS 47mm WC Cu w/ Busbar + spirol pins fitted (10mm Hose) XW076NC16BT mm WC Cu w/ Busbar + thermostat hole (10mm Hose) 16 XW076NC16C 47mm WC Cu w/ Busbar (1/2" Hose) XW076NC16CT 47mm WC Cu w/ Busbar + thermostat hole (1/2" Hose) XW076NC16R mm WC Cu reversed with Busbar XW076NC16W N/A 47mm WC Cu reversed XW116ZC20A N/A 73mm WC Cu XW116ZC20B mm WC Cu with Busbar XW116ZC20C mm WC Cu with alt. Busbar XW116ZC20R mm WC Cu reversed with Busbar XW116ZC20W N/A 73mm WC Cu reversed XW127EN15A 85mm WC Al Nitride N/A XW127EN15B 85mm WC Al Nitride without holes XW127EC25A N/A 85mm WC Cu Helix XW127EC25B mm WC Cu with Busbar Helix XW127EA25A N/A 85mm WC Al Helix 25 XW127EA25B mm WC Al with Busbar Helix XW160FC25A N/A 100mm WC Cu XW160FC25B mm WC Cu with Busbar XW180GC34A N/A 125mm WC Cu Helix XW180GC34B mm WC Cu with Busbar Helix 34 XW180GA34A N/A 125mm WC Al Helix XW180GA34B mm WC Al with Busbar Helix XW180GN25A N/A 125mm WC Al Nitride Helix 25 XW270QA25A n/a 270 x mm WC Al Cold Plate XW116ZC20C XW127EN15A Part No. XSNM12H10S XSNM12H12S XSNM10H15P Accessory Description M12 Cooler Connection, 10mm Hose & Stainless Steel material M12 Cooler Connection, 12mm Hose & Stainless Steel material M10 Cooler Connection, 15mm Hose & Plastic Material For outline drawings and dimensions please see the IXYS Selector guide IUK-TSM Issue /05/2016
16 Other accessories and lead sets Part No. XSGSCX13 Accessory Press Pack Semiconductor Mounting Grease (1kg tub) XST1000M08P XST1000M10P XST1000M12P XST1000M16P M8 PTFE tube x 1m length insulation M10 PTFE tube x 1m length insulation M12 PTFE tube x 1m length insulation M16 PTFE tube x 1m length insulation Dimension Insulator capsules A B C mm mm mm L0001YC450XXX 30mm diameter poleface Insulator Capsule L0001QC450XXX 43mm diameter poleface Insulator Capsule L0001MC450XXX 56mm diameter poleface Insulator Capsule L0001HC450XXX 68mm diameter poleface Insulator Capsule L0001TC450XXX 87mm diameter poleface Insulator Capsule L0001FC450XXX 100mm diameter poleface Insulator Capsule Part No. Lead dimension and termination Device type XSL220C2WRT 220mm long twisted pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL300C2WRP 300mm long pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL300C2WS 300mm long gate wire, Silicone sleeve cable 16/0.2, White, M4 ring terminal Thyristor XSL350C2WRP 350mm long pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL400C2WRP 400mm long pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL500C2WRP 500mm long pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL600C2WRP 600mm long pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL1000C2WRP 1000mm long pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL1000C2WRT 1000mm long twisted pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor XSL1100C2WRT 1100mm long twisted pair, Silicone sleeve cable 16/0.2, Red / White, M4 ring terminal Thyristor Langley Park Way Chippenham, SN15 1GE United Kingdom Tel: +44 (0) Fax: +44 (0) sales@ixysuk.net Edisonstr. 15 D Lampertheim Germany Tel: +49 (0) Fax: +44 (0) marcom@ixys.de IXYS UK Westcode Ltd s BS EN ISO9001 quality system is registered by BSI We are supported by a global network of local offices, representatives and distributors. Please visit our website for more information IUK-TSM Issue /05/2016
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