power semiconductor assemblies, components and custom ... · pdf filepower semiconductor...

IUK-TSM-2014-004 Issue 4 1 04/05/2016

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 multi-

megawatt 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 300m2 dedicated

production facility complemented by a well-

equipped 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-2014-004 Issue 4 2 04/05/2016

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

Step 1 - Problem

Step 2 - Design

Step 3 - Manufacture

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

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

3-level inverter assembly

Another example of a bespoke design from IXYS UK is the

force air-cooled three phase fully controlled bridge, 1850ADC

@ 55°C, 500VRMS 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 3430ADC for 10s

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-2014-004 Issue 4 3 04/05/2016

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

Standard assemblies

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

Press-pack IGBT 3-level inverters

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-2014-004 Issue 4 4 04/05/2016

6.6kV system 10kV system

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 water-

cooled or forced air cooled. Please contact IXYS UK for more information.

Power Rating (MW) 12


No. of IGBT’s 4

No. of Diodes 4

No. of Coolers 5

Required IGBT Type T1600GB45G


Power Rating (MW) 16


No. of IGBT’s 6

No. of Diodes 6

No. of Coolers 7

Required IGBT Type T1600GB45G


Phase leg schematic Phase leg schematic

IUK-TSM-2014-004 Issue 4 5 04/05/2016

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-2014-004 Issue 4 6 04/05/2016

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

IUK-TSM-2014-004 Issue 4 7 04/05/2016

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

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

WESPACK devices provide maximum

power rating for weight and volume

without compromising on quality and

reliability

Figure 1 Figure 2 Figure 3

IUK-TSM-2014-004 Issue 4 8 04/05/2016

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

WC64

Easy mount standard rectifier assemblies

WC65

WC66

Part No. Base Polarity

VRRM ITAV

ITSM i2t VT0 rT Rth TJM Outline TC –

100°C V A kA A2s V mΩ K/W °C

W1185LC450KBR † Anode 4500 435 10.2 520×103 1.00 0.575 0.085 160 WC64

W1185LC450KBN † Cathode 4500 380 10.2 520×103 1.00 0.575 0.101 160 WC64

W1411LC360KBR † Anode 3600 505 12.2 744×103 0.90 0.388 0.085 160 WC64


W1524LC300KBR † Anode 3000 540 13.4 898×103 0.87 0.323 0.085 160 WC64


W1748LC220KBR † Anode 2200 660 13.5 911×103 0.87 0.28 0.085 175 WC64


W2058LC120KBR † Anode 1200 760 16.1 1.30×106 0.79 0.192 0.085 175 WC64

W2058LC120KBN † Cathode 1200 665 16.1 1.30×106 0.79 0.192 0.101 175 WC64

W1185LC450KCR Anode 4500 455 10.2 520×103 1.00 0.575 0.08 160 WC65

W1185LC450KCN Cathode 4500 395 10.2 520×103 1.00 0.575 0.097 160 WC65

W1411LC360KCR Anode 3600 530 13.2 756×103 0.90 0.388 0.08 160 WC65


W1524LC300KCR Anode 3000 565 13.4 898×103 0.87 0.323 0.08 160 WC65


W1748LC220KCR Anode 2200 690 13.5 911×103 0.87 0.28 0.08 175 WC65


W2058LC120KCR Anode 1200 800 16.1 1.30×106 0.79 0.192 0.08 175 WC65

W2058LC120KCN Cathode 1200 690 16.1 1.30×106 0.79 0.192 0.097 175 WC65

W3082MC450KDR Anode 4500 1115 26.6 3.54×106 0.923 0.192 0.037 160 WC66

W3082MC450KDN Cathode 4500 1030 26.6 3.54×106 0.923 0.192 0.041 160 WC66

W3708MC350KDR Anode 3500 1240 33.7 5.68×106 0.958 0.112 0.037 160 WC66


W3842MC280KDR Anode 2800 1325 33.5 5.61×106 0.831 0.118 0.037 160 WC66


W5636MC150KDR Anode 1500 2035 43.9 9.64×106 0.698 0.059 0.037 175 WC66


† - Assembly supplied as kit of parts, all other designs available as either kit of parts or fully assembled

IUK-TSM-2014-004 Issue 4 9 04/05/2016

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

Custom assemblies – traction applications

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

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

4MW, 1500VDC traction rectifier

IUK-TSM-2014-004 Issue 4 10 04/05/2016

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

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

Design

3D Modelling

Realisation

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

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

IUK-TSM-2014-004 Issue 4 11 04/05/2016

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 190°C junction temperature.

Supporting components – Precision bar clamps

Range Part Number Force

Max Cell Diameter

TJMAX

kgf mm °C

XSK042

XSK00500DA042Mxxx 500 42 190

XSK00500DT042Mxxx 500 42 190

XSK00500DF042Mxxx 500 42 190

XSK065

XSK01500DA065Mxxx 1500 65 190

XSK01500DT065Mxxx 1500 65 190

XSK01500DF065Mxxx 1500 65 190

XSK075

XSK02200DA075Mxxx 2200 75 190

XSK02200DT075Mxxx 2200 75 190

XSK02200DF075Mxxx 2200 75 190

XSK087

XSK03000DA087Mxxx 3000 87 190

XSK03000DT087Mxxx 3000 87 190

XSK03000DF087Mxxx 3000 87 190

XSK103 XSK03200DA103Mxxx 3200 103 190

XSK03200DF103Mxxx 3200 103 190

XSK112 XSK#####DA112Mxxx 3800/4500 112 190

XSK#####DF112Mxxx 3800/4500 112 190

For outline drawings and dimensions please

see the IXYS Selector guide

IUK-TSM-2014-004 Issue 4 12 04/05/2016

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

XSK1500DA076038 M8 x 90 M8 x 60

89 32 10-20

38

XSK1500DA076076 M8 x 130 M8 x 95 76

XSK1500DA076101 M8 x 160 M8 x 120 101

XSK2000DA076038 M8 x 95 M8 x 60

89 38 13-20

38

XSK2000DA076076 M8 x 130 M8 x 95 76

XSK2000DA076101 M8 x 160 M8 x 120 101

XSK3000DA076038 M8 x 100 M8 x 65

89 50 25-31

38

XSK3000DA076076 M8 x 130 M8 x 100 76

XSK3000DA076101 M8 x 160 M8 x 125 101

XSK3400DA076038 M8 x 100 M8 x 65

89 50 27-34

38

XSK3400DA076076 M8 x 140 M8 x 105 76

XSK3400DA076101 M8 x 160 M8 x 130 101

XSK3800DA116M076 M10 x 150 M12 x 100 132 66 32-38

76

XSK3800DA116M101 M10 x 180 M12 x 125 101

XSK4400DA116M076 M10 x 150 M12 x 105 132 68 36-44

76

XSK4400DA116M101 M10 x 180 M12 x 130 101

XSK6000DA116M076 M10 x 150 M12 x 105 132 75 50-60

76

XSK6000DA116M101 M10 x 180 M12 x 130 101

Box Clamps

Part No. Moulded box

style

Fixing centres

Bolt size

Capsule device

Outline Ref. Outline

Mounting surface

diameter

Nominal thickness

mm mm mm mm

XK0450BA019M Injection 50 PCD M5x50 DO-200AA/TO-200AB 19.0 13.8 WC48

XK0450BB019M Compression

XK0450BA025M Injection 50 PCD M5x50 DO-200AA/TO-200AB 25.0 14.6 WC49

XK0450BB025M Compression

XK1500BA034M Injection 70 PCD M6x50 DO-200AB/TO-200AC 34.0 26.2 WC50

WC48/49 WC50 For outline drawings and dimensions

please see the IXYS Selector guide

IUK-TSM-2014-004 Issue 4 13 04/05/2016

Standard Bar Clamps

Part No.

Fixing centres

Bolt size

Capsule device

Outline

Mounting surface

diameter

Nominal thickness

TJM

mm mm mm mm °C

XK0450DA056M 65 M8 DO-200AA/TO-200AB 19.0 13.8 190 XK0450DT056M

XK0450SA056M XK0550DA056M

65 M8 GTO 29.5 16.0 190 XK0550SA056M XK0900SA056M 65 M8 Diode/Thyristor 25.1 14.6 190 XK0600DA074M

89 M10 Press-Pack IGBTs 47.0 27.0 190 XK0600SA074M XK1000DA074M

89 M10 Press-Pack IGBTs 47.0 27.0 190 XK1000SA074M XK1100DA076M 89 M10 DO-200AB/TO-200AC 34.0 26.2 190 XK1130DA076M

89 M10 DO-200AB/TO-200AC 34.0 26.2 190

XK1130DT076M 190 XK1130SA076M 190 XK1800DA076M

89 M10 Wespack PCT 38.0 14.0 190 XK1800DT076M XK1800SA076M XK2100DA076M

89 M10 GTO 47.0 27.0

190 XK2100DA076ML 125 XK2100SA076M 190 XK2100SA076ML 125 XK2140SA076M

89 M10 D0-200/Thyristor 47.0 26.8 190

XK2140SA076ML 125 XK2700DA076M

89 M10 Wespack PCT 50.0 14.0 190 XK2700DT076M XK2700SA076M XK2000DA114M



132 M12 GTO 63.0 26.0


132 M12 D0-200AD/Thyristor 63.0 33.0 190

XK3000SA116ML 125 XK3500DA116M

132 M12 GTO 75.0 26.0


132 M12 Diode/Thyristor 73.0 36.8 190

XK4000SA116ML 125 XK5000DA128M

146 M16 GTO 75.0 26.0 190

XK5000DA128ML 125 XK7000DA128M

146 M16 Diode/Thyristor 75.0 26.6 190

XK7000DA128ML 125 XK3060DA140ML

154 M12 Press-Pack IGBTs 85.1 26.0 125 XK3060SA140ML XK9000SA160M

180 M16 Thyristor 99.3 35.8 190

XK9000SA160ML 125 XK9000DA160M

180 M16 Thyristor 99.3 35.8 190

XK9000DA160ML 125 XK6120DA180ML

196 M16 Press-Pack IGBTs 125.0 26.0 125 XK6120SA180ML

IUK-TSM-2014-004 Issue 4 14 04/05/2016

Heatsinks

Part No. Weight Periphery Area

Figure kg mm mm2

XSFGxxxxAN 8.1 1059 2979 WH1

XSFGAxxxxAN 15.6 1682 5867 WH2

XSFHxxxxAN 12.7 1684 4655 WH3

XSFTxxxxAN 20 2065 7573 WH4

XSFTBxxxxAN 29 2467 10905 WH5

XSFTCxxxxAN 28 2544 10561 WH6

SXFLPxxxxAN 30 6620 11172 WH7

SXF46xxxxAN 20 2822 7411 WH8

SXF30xxxxAN Dimensions 125mm x 125mm x 4 vanes WH9

WH1

WH2

WH7

WH3

WH6

WH9

WH4

WH5

WH8

For outline drawings and dimensions


IUK-TSM-2014-004 Issue 4 15 04/05/2016

Coolers and Cooler Accessories

Part No. Weight Cooler Thickness Busbar Thickness

Description kg mm mm

XW076NC16A 0.418

16

N/A 47mm WC Cu

XW076NC16B

0.612 6.4

47mm WC Cu w/ Busbar (10mm Hose)

XW076NC16BS 47mm WC Cu w/ Busbar + spirol pins fitted (10mm Hose)

XW076NC16BT 47mm WC Cu w/ Busbar + thermostat hole (10mm Hose)

XW076NC16C 47mm WC Cu w/ Busbar (1/2" Hose)

XW076NC16CT 47mm WC Cu w/ Busbar + thermostat hole (1/2" Hose)

XW076NC16R 0.581 6.35 47mm WC Cu reversed with Busbar

XW076NC16W 0.400 N/A 47mm WC Cu reversed

XW116ZC20A 1.300

20

N/A 73mm WC Cu

XW116ZC20B 1.750

10

73mm WC Cu with Busbar

XW116ZC20C 2.120 73mm WC Cu with alt. Busbar

XW116ZC20R 1.672 73mm WC Cu reversed with Busbar

XW116ZC20W 1.119 N/A 73mm WC Cu reversed

XW127EN15A 0.375 15 N/A

85mm WC Al Nitride

XW127EN15B 85mm WC Al Nitride without holes

XW127EC25A 1.650

25

N/A 85mm WC Cu Helix

XW127EC25B 2.200 8 85mm WC Cu with Busbar Helix

XW127EA25A 0.500 N/A 85mm WC Al Helix

XW127EA25B 0.650 8 85mm WC Al with Busbar Helix

XW160FC25A 3.620 N/A 100mm WC Cu

XW160FC25B 4.520 10 100mm WC Cu with Busbar

XW180GC34A 4.920

34

N/A 125mm WC Cu Helix

XW180GC34B 5.950 10 125mm WC Cu with Busbar Helix

XW180GA34A 1.500 N/A 125mm WC Al Helix

XW180GA34B 1.800 10 125mm WC Al with Busbar Helix

XW180GN25A 0.920 25

N/A 125mm WC Al Nitride Helix

XW270QA25A 2.941 n/a 270 x 190mm WC Al Cold Plate

XW116ZC20C XW127EN15A

Part No. Accessory Description

XSNM12H10S M12 Cooler Connection, 10mm Hose & Stainless Steel material

XSNM12H12S M12 Cooler Connection, 12mm Hose & Stainless Steel material

XSNM10H15P M10 Cooler Connection, 15mm Hose & Plastic Material

For outline drawings and dimensions


IUK-TSM-2014-004 Issue 4 16 04/05/2016

IXYS UK Westcode Ltd’s BS EN ISO9001

quality system is registered by BSI

Langley Park Way

Chippenham, SN15 1GE

United Kingdom

Tel: +44 (0)1249 444524

Fax: +44 (0)1249 659448

E-mail: [email protected]

Edisonstr. 15

D-68623 Lampertheim

Germany

Tel: +49 (0) 6206 503-0

Fax: +44 (0) 6206 503627

E-mail: [email protected]

We are supported by a global network of local offices, representatives and distributors. Please visit our website for more information

www.ixysuk.com www.ixys.com

Other accessories and lead sets

Part No. Accessory

XSGSCX13 Press Pack Semiconductor Mounting Grease (1kg tub)

XST1000M08P M8 PTFE tube x 1m length insulation




Insulator capsules

Dimension

A B C

mm mm mm

L0001YC450XXX 30mm diameter poleface Insulator Capsule 30 42 15.1

L0001QC450XXX 43mm diameter poleface Insulator Capsule 38 58.5 14.5

L0001MC450XXX 56mm diameter poleface Insulator Capsule 47 74 27.7

L0001HC450XXX 68mm diameter poleface Insulator Capsule 68 100 14.5

L0001TC450XXX 87mm diameter poleface Insulator Capsule 73.1 110.5 35

L0001FC450XXX 100mm diameter poleface Insulator Capsule 75 112 26.6

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








power semiconductor assemblies, components and custom ... · pdf filepower semiconductor...

Documents