DC Link Power Ring Film Capacitors TM & Integrated Capacitor/Bus Structures For Wind, Solar and Network Power. Over Half a Century of Expertise

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1 DC Link Power Ring Film Capacitors TM & Integrated Capacitor/Bus Structures For Wind, Solar and Network Power Over Half a Century of Expertise

2 Contents SBE Company Overview Power Ring Technology Power Capacitors and Integrated Cap/Bus offerings Performance Drop-in Capability DC Link vs. Energy Storage Field Trial Simplicity

3 Who we are Leading developer and manufacture of film capacitor solutions Making capacitors as Sprague since 1945 independent since 1986 Over 1 Billion capacitors manufactured Vast experience in solving power electronic problems Markets include Transportation, Alternative Energy, UPS & Network Power, Medical/Laser, Military

4 SBE Corporate Overview Established: 1986, spin off of Sprague Electric. Capacitor production dates back to 1945 as Sprague. Locations: Headquarters, Manufacturing and R&D Center: Barre, Vermont Application Engineering and Sales: Colorado and Xiamen China New plant constructed in 2010 Facilities: 53,000 square feet new facility with capacity for over 100,000 electric drive vehicles by 2012 China: engineering and assembly 5,000 square feet Distributors: Future Electronics worldwide Richwood China and Hong-Kong Jin Zon Taiwan Ownership: Privately Held Corporation Employees: 50 Sales: Estimated at $10M Executive Team: Ed Sawyer, President & CEO Tom McBride, Executive Vice President Bob Britt, Chief Financial Officer Michael Brubaker, VP of Engineering and CTO Mike Olsen, Vice President of Sales Mark Browning, VP, Customer/New Product Development

5 SBE Core Competencies Technology Innovator: Six global patents on Pulse and Power Ring technology US Department of Energy R & D grant recipient for advanced DC Link Capacitor Technology Awardee of $9.1 Million DoE grant ($18 Million project for new facility and equipment) Superior Performance Highly Responsive with Short Lead Times 4 to 6 Weeks typical 8 weeks proto Collaborative Application Engineering Global Supplier New Plant, State-of-the-Art Facility: Highly automated equipment Efficient Class 10,000 Clean Room ISO-9000, UL, ASTM/IEC, (CE Pending) TS Active Roadmap to 2015

6 Representative Customers

7 World Class Manufacturing and Engineering Large volume production capacity $19M DOE matching grant funded expansion to supply capacitors for over 100,000 electric vehicles per year Adapted for solar/wind as well Robust procurement system assuring lowest cost Sourcing, engineering and sub-assembly facility in China Committed roadmap to duplicate final assembly/test in China as volume warrants. 12 month transition est. Research, development and application Engineering in Colorado and Vermont Expertise in system integration and optimization Industry leading testing capabilities 2 facility winding for risk mitigation

8 SBE Power Ring Film Capacitors Film Capacitor Technology Overview

9 SBE Power Ring Film Capacitors Why film vs. other dielectrics such as ceramic and aluminum electrolytic High reliability Capacitance stability over temperature and frequency Greater current carrying capability Low ESR/Losses Self-healing characteristics However, less capacitance and energy density

10 The Power Ring Advantage Film is film to all capacitor vendors. Everyone has access to the same global film suppliers. Key is to understand how to exploit the film properties to achieve its best performance. Form Factor Film thickness Metallization

11 The Power Ring Advantage SBE has targeted the Ring form factor to provide the best possible performance and life. Significant investment in proprietary winding technology. High value of knowledge through R&D. Performance at system integration level.

12 Power Ring Form Factor Advantage Power Ring v. Traditional Can Style Short current path = less resistance=less heat generation Large surface area and short thermal path for optimized heat removal Lower t-rise for same ripple current Longer Life Handle same current with fewer micro-farads Ideal for Large Monolithic Capacitors Lower Cost Fewer Failure Points Better Performance

13 Same capacitance (1.5mF) more current capability and lifetime with a Power Ring

14 Lifetime with same ripple current rating (350A) at 55 C ambient

15 Compare Form Factor 55.8 C 89.6 C 4 x 250 µf cans Power Ring 1000 µf 1000 µf Polypropylene Film Capacitor(s) 200 A rms ripple at 5 khz 55 C Boundary Conditions - 4x Cans in Parallel - Single Power Ring

16 1000 µf, 600 V, 200 Arms ripple 20 khz Internal thermo-couples installed in the core of the winding SBE Temperature Rise

17 Key Technology Factors Single monolithic winding: Better performance and fewer failure points than a bank of multiple smaller parts. Short current path provides very low ESR and losses ( μω typical per part) Large thermal cross section area provides for efficient heat removal: Minimal hot spot temperature rise. Best possible current rating for given capacitance. Optimized terminal structure provides very low ESL (3 7nH typical) UL recognized

18 System Benefits Highest current ratings per micro-farad Reduce your DC Link micro-farads and save cost and volume Greatly increase you system s maximum safe current rating with the existing cost and volume budget (double power same cost) Reduce your cooling needs with less dissipated losses Reduce cost Increase power density for a given cooling design Reduce volume Increase your semiconductor s safe, usable voltages Lowest ESL/eliminate snubbers Get more power from your selected IGBT vendor product Utilize 1000V bus voltage with 1200V die Reduce performance compromises in your driver architecture

19 SBE 700D590 Power Ring Cap = 1500µF Voltage = 1100V ESR = 300µΩ ESL < 15nH Current 350A Life 200,000 hrs. (50 C)

20 Power Ring Built for Life (example of a single 1500µF capacitor) Low ESR < 300µΩ Low Thermal Resistance Lowest possible hotspot temperature per Ampere of ripple current = long life

21 Compare ESL Inductance Contribution 4x 250µF Cans Typical Bus 1000µF Power Ring Optimized Bus IGBT 10nH 10nH IGBT Interconnect 7nH 3nH Bus 5nH 5nH Capacitor 12.5nH 3.2nH Total 34.5nH 21.2nH Fixed 40% less voltage overshoot = Increase DC bus voltage and harvest more kw per dollar invested in silicon Even better ESL is possible with SBE integrated capacitor and bus technology

22 Power Ring Summary Large monolithic winding for lower cost and smaller size package Reduce failure points Short current path provides very low ESR Low losses/t-rise Large thermal cross section area provides efficient heat removal Best possible current rating for given capacitance Optimized terminal structure provides very low ESL Increase bus voltage with existing switches Virtually eliminates current hogging

23 The Power of the Ring SBE Power Ring - Enabling state of the art integration

24 Integrated Cap/Bus SBE s integrated bus/cap solutions offer the lowest ESL seen at the IGBT pins Maximize bus voltage Lowest industry ESR and T-Rise means longer life Simplify manufacturing Reduced failure points Improve costs Immediate reduction in capacitor costs Reduce manufacturing costs (reduced labor and material costs) Reduce system maintenance costs Protect and Maximize Your IGBT

25 Integrated Cap/Bus Cont d Power Density Joint SBE/Danfoss Silicon Power Project Double the power density! 1MW inverter in same space previously occupied by 500kW Low inductance allowed for complete elimination of snubber capacitors 1100Vdc

26 Drop-in Replacements - Example Film to film drop-in Integrated designs for drop-in replacement Protect your IGBT with lowest ESL Lowest ESR and T-rise = long life Improved cost, or Up to twice the power in the same space and cost 10pcs x 400µF/ 1100Vdc 300A rating at 55 C 4x 500µf/1100Vdc 450A rating at 55 C How is this possible? Fewer Power Rings Can Handle the Full Bank Current

27 Drop-in Replacements - Example 10 x 400μF -> 4000 μf bank Electronicon Example: E50 N13-404N50* 1100V nominal 300A total current possible (10 x 30A - cooling at 60 C) Current hogging limited? 40nH ESL each total depends on assembly SBE estimates 25nH 0.4mΩ ESR total bank Lifetime expected at nominal voltage : 100,000 hours *All information from Electronicon datasheet

28 SBE Comparison Example: 2 x 700D590 Electrical description 2pcs x 1500 μf/ 1100Vdc Total:3000 μf/1100vdc 2 x 1500μF -> 3000 μf bank 1100V nominal More than 700A continuous and 1000A+ peak 15nH ESL at IGBT terminals 0.12mΩ ESR Lifetime expected at nominal voltage > 200,000 hours Similar W x L dimensions as 4000 μf Electronicon bank

29 SBE Drop-in Success Story Approached by customer experiencing field failures and looking for design improvements SBE proposed two separate options for customer consideration

30 SBE Drop-in Success Story The Problem Current hogging at certain capacitor sections Catastrophic field failures Expensive vs. power Half cut away µF 1500Vdc Capacitor - full view external

31 Current Hogging What s good can be bad! The evidence of surprisingly low overshoot is not good fortune. It is usually evidence that one cap is dominating the low impedance path providing an abnormal ESL vs. expected but also filtering more current than planned. The current hogging cap is almost always the first to fail and the weak link. SBE can find this by simulating, doing passive ring out and overshoot tests and comparing the results. Wide discrepancies in your existing system are predicting failure points in the field. Power Ring assemblies show very little current hogging in typical examples with balanced IGBT connection points

32 SBE Drop-in Success Story SBE Basic Solution Match terminal structure Improved but compromise ESL Current distribution significantly better than original cap Current hogging issue resolved but not optimized 2600µF 1500Vdc

33 SBE Drop-in Success Story SBE Optimized Solution Two windings with crown terminals for uniform current distribution µF 1500Vdc, 50% more power Best-in-class ESL Eliminated current hogging Not terminal-to-terminal match but bus structure and volume drop in

34 SBE Drop-in Success Story Outcomes: SBE successfully replaced a 10 section traditional film capacitor system with a 2 Power Ring solution Customer opted for the basic solution for quick drop-in adoption with existing terminal connections Customer has known optimized solution for performance upgrades during future design cycle with SBE unique terminal system

35 Fully Integrated Optimized Design Next Iteration Integrated capacitor/bus structure Lowest possible ESL enables 1200V IGBT with 1000V bus Fewer failure points Further cost reduction over original designs but 50% more power 2600µF 1500Vdc 400kW

36 Other SBE Optimized Integrated Solutions

37 700A163 Integrated Module 700A Vdc, 3000μF DC Link Film Capacitor 700Arms with 200,000 hours life ESR 150 micro-ohms at 20kHz ESL - Less than 10 nh at the typical half bridge type package connection Operating Temperatue: -40 C to +85 C hotspot temperature at full DC voltage rating

38 SBE Power Ring Module High Density Module for 50kW 100kW String Inverters Specifications 100µF at 1100V 220µF at 600V 350µF at 450V Integrated capacitor and laminated bus Shared cooling for IGBT, bus & capacitor Liquid or Air cooled Low ESR; < 500 micro-ohm Low ESL; < 10nH Modular building block for higher power systems

39 500kW DC Link Solution External size: 750 X 595 X 68 mm External size: 530 X 380 X 140 mm 777A uf/1100vdc ESR 150 micro-ohms at 20kHz ESL 10nH 777A uf/1100vdc ESR 150 micro-ohms at 20kHz ESL 10nH

40 4400µf 1100Vdc Example Using Half Bridges A 500kW long life low cost system

41 3000µf/1100Vdc Example Using Half Bridges A 500kW low cost long life system

42 1500µF 700Vdc Example Conforming to Existing Customer space A 250kW low cost long life system

43 3 x 1500µF 1100Vdc Example Half Bridge per Phase A 500kW low cost long life flexible system Confidential and Proprietary

44 System Benefits Summary Much higher current ratings per micro-farad Reduce your DC Link micro-farads and save cost and volume Greatly increase your system s maximum safe current rating with the existing cost and volume budget (double power same cost) Reduce your cooling needs with less dissipated losses Reduce cost Increase Power Density for a given cooling design Reduce volume Increase your semiconductor s safe, usable voltages Get more power from your selected IGBT vendor product Utilize 1000V bus voltage with 1200V die Without the use of snubber capacitors or other additional hardware Reduce performance compromises in your driver architecture

45 SBE Bank Hardener TM The Best of Both Worlds

46 SBE s Bank Hardener Where capacitor bank volume/energy storage is a necessary value for your system Use the superior RMS current handling capability of the Power Ring to provide most of the current, giving the rest of the storage bank a light ride Depends on the capacitor ratio and the relative ESRs The worse the ESR, the better the effect More supply chain flexibility and cost opportunities Bus structure can manipulate the effect

47 SBE s Bank Hardener SBE s Bank Hardener offers the best of both worlds The energy storage capacity of Aluminum Electrolytic and the ripple current capability of Film Improve Cost Immediate reduction in capacitor costs Reduce manufacturing costs (reduced labor and material costs) Reduce maintenance costs Low T-rise, Increase Life The designed T-rise in the Electrolytic bank is greatly reduced Reduce Failure Points Increase Inverter Power Smaller Form Factor or Drop-in Replacement as needed

48 SBE s Bank Hardener Without Bank Hardener: 36,000 µf 1500Vdc 400Arms 120,000 hour lifetime With Bank Hardener: 19,500 µf AE bank reduced by ½ Add 1,500 µf Power Ring Bank Hardener 1500Vdc 400Arms 120,000 hour lifetime Increase life and/or increase inverter power with fewer capacitors SBE s Bank Hardener - The Next Step in Capacitor Technology

49 SBE s Bank Hardener Power Rings take an increasing amount of current as frequency increases Protects aluminum electrolytic caps and increases life SBE s Bank Hardener - Spend Less and Get More!

50 SBE s Bank Hardener The low pass filter effect of the bank hardener is applied to the entire spectral content of the switching artifacts of the inverter A significant percentage of the energy is occurring at 3, 5, 7 and 9x harmonics of the primary switching frequency The aluminum electrolytics are highly sensitive to life degradation at these higher harmonics

51 SBE s Bank Hardener Equivalent Switching Frequency

52 SBE s Bank Hardener The desired results SBE s Bank Hardener Spend Less and Increase Life

53 SBE s Bank Hardener Resonance can be a serious problem The bank hardener is designed as a system to eliminate this issue Taper impedances in the bus and interconnections Make certain that resonant frequencies are not sitting on top switching harmonics Electrolytic resonance is pushed well beyond 100kHz where there is not much energy Film capacitor is rated for the total ripple current over the full frequency spectrum

54 Example Bank Hardener 3x 400µF, 1100V power rings and 1.8mF electrolytic bank 230Arms Each 400µF power ring is rated at 127Arms The electrolytics limit the life of this bank

55 Example Bank Hardener Add 1.2mF film capacitor to harden existing 1.8mF electrolytic bank

56 Example Front End Capacitor for Bank Hardener 1100V, 750µF capacitor can manage 230A ripple current

57 SBE s Bank Hardener Flexible Implementation Examples Integrate high performance film capacitors on a bus structure Tightly integrated with the switch elements Low ESL and minimal current hogging If additional capacitance is needed, consider a side-car bank of electrolytic cans to provide slow energy storage Side-car bank concept has better performance if connection to power ring has higher impedance All designs can be validated by simulation SBE s Bank Hardener Spend Less and Increase Life

58 Summary SBE technology enables: Reduced Costs Immediate reduction in capacitor costs Reduced manufacturing costs (reduced labor and material costs) Consolidated Supply Chain (Up-Integration and source flexibility) Reduced system maintenance costs and downtime Increased Reliability Low ESR (Low T-rise = Increased Life) Reduced Failure Points Designed out resonance concerns Increased Inverter Power Lower ESL = Maximize IGBT efficiency Higher Ripple Current in the same cap bank size Drop-In replacements System Optimization for next generation product launches

59 Try a Power Ring AC Filter Cap Bank Increase Life Eliminate catastrophic failures Increase Reliability Dry Film Construction DC Link Capacitors Leading Power Density Improved Performance UL Recognized Options Test Kits Horizontal or Vertical Integrated Modules Optimized Solutions Low ESR & ESL Shared Cooling Adapters available for popular IGBT s Extreme Energy Pulse Power Pulse/HV Capacitors DC Voltage up to 100kV Small sizes up to 100uF/ 500kV Cap up to 12,000uF Power Rings up to 3000uF/8kV Innovative Packaging Can be stacked for greater voltage

60 Try a Power Ring SBE Test Kits (see the performance first hand) SBE provides test kits with adaptors for a variety of IGBTs Vertical Test Kits Horizontal Test Kits SBE s advanced simulation and testing tools can accurately measure: ESL Temperature Rise (and thus accurately predict life) Overshoot Integrated Capacitor/Bus design services & procurement Talk to our world class design staff and obtain the benefits!