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PCC HPTM High-Power Capacitors for Heavy-Duty Applications

Product Profile 2000

2 EPCOS AG

connected to performance

3EPCOS AG

PCC HPTM High-Power Capacitors for Heavy-Duty Applications

GeneralInnovative products are con-quering the markets of the future. PCC HPTM (Power CapacitorCompact – High Power) fromEPCOS in Heidenheim is aninnovative component in driveengineering. All the demands ofmodern drive and inverter systemsflowed into its design. Developedfor quality, the emphasis in PCCwas also on cost savings, fromsystem design through operationto disposal at the end of productlifetime. Application of mature and

sophisticated inhouse technologywith long experience in the fieldguarantees a high-grade product that is fully in line with the trendtowards minimum dimensions plusenhanced performance.

PCC HP applicationsClassic applications in traction and for large or megastationary drive systemsa Link capacitorsa Series resonant circuit capacitors

New applicationsa Industrial (drive systems,

SIV, SVG)a DC transmission systems a DC energy storage for power

quality systemsa Power pulsed current (pulse

magnetizer, laser, welding,pulsed voltage apparatus)

a High power inverter drivesystems (ship, mining, etc.)

System solutions for all semiconductorsa IGBT a GTOa IPM a etc.a GCT

AdvantagesElectricala Long service lifea Low self-inductance

(approx. 30 nH)a High current handling

(≤ 300 Arms)a Absence of partial discharge

Mechanicala Reduced volume and weight a No mounting position

restrictionsa Fixings on requesta Maintenance-free

Safetya Dry technology (oil free)a Self-healing (SH)a Non-flammable

(NFF regulations)

Environmenta NPCB (PCB free product)a Environment friendlya Simple disposal

maintenance free

4EPCOS AG4

Contents

a General 3

a Overview – applications 3Advantages: electrical, mechanical, safety, environment

a Reasons for choosing PCC-HP 5

a Technology demands 6Basic technical information

a The PCC-HP concept 7PCC-HP heavy duty applications

a Technical data 8/9MKK dry technology, metalization, cutting and winding, safety (SH, FF), maintenance and environment

a Design features 10/11Power-ranges, standard dimensions, terminals, design hintsOutline drawings with dimensions

a Designs for different applications 12/13Drive systems’ power ranges and basicapplication block diagrams

high performance

PCC HPDC-Link

3~Transformer

~= =

~Rear-EndInverter

Front-EndConverter

15 kVAC 16 2/3 HzAC-Traction System

ASMASM

Technology demands

6 EPCOS AG

tougher requirements on MKK DC capacitors’ performanceas key components in linkinverters.

The PCC concept results in newapplications and cost benefitscompared to traditional high-power IGBT inverter applica-tions.

Applications – basic informationThree-phase drives of very highpower, with low-losses, symmetri-cal GTO phase modules, alreadyuse a low-inductance link bankbased on MKK technology (M = metalized, K = Kunststoff /plastic film, K = kompakt /compact).PCC concept continues the expe-rienced dry MKK technology, since the latter was launched over15 years ago. Far more than amillion MKK capacitors have goneinto diverse applications world-wide since then. High reliabilityand long lifetime show in anextremely low failure rate in thefield: <100,000 h use for αAQ of≤ 300/109 h.

The newly developed PCC HPcapacitor (P = power, C = capacitor,C = compact, H = high, P = power)is mounted straight onto a semi-conductor via busbar.At low power levels (industrial andautomotive) there is now also afirm requirement for higher switch-ing frequencies and operatingcurrents free of oscillation. For certain applications the ther-mal characteristics and lifetime ofPCC being superior to electrolytictechnology. Design and process improvementsare continuously enhancing theperformance of MKK technology.New applications like HEVs (hybridelectric vehicles), ISG (integratedstarter generator) and laser areconsequently opening up next totraditional use in link and seriesresonant circuits for traction andsimilar industrial applications.

metalization

flame-spraying(shopping layer)

demetalizedarea

polymerfilm layer

free margin

PCC-stack

The new demands of the latestsemiconductor generation setnew standards for the designof MKK DC capacitors. The new 6.5 kV IGBT modulefor inverters was presented atthe PCIM Europe 99.

This shows the way to invertersin the kW to MW range, at the same time speeding up thereplacement of GTO semicon-ductor valves. The technologicalevolution means substantially

7 EPCOS AG

The PCC concept

PCC concept prove optimum incutting the costs of producingnew inverter models. Its flexi-bility offers custom solutionsfor decisive design, system andcost benefits. A newly developed connectorbetween the IGBT and PCCproduces the extremely lowinductances that optimizeinverter performance. Versionswith two facing, compositefiber platforms thus hold extrapromise for creating moderninverter designs.

PCC HP for heavy dutyapplicationsThe capacitor sets up on a platformof fiberglass-reinforced polyester(composite fiber) that satisfies allmajor fire-hazard standards. Thewindings (flat or MPM; M = metal-ized, P = polymer, M = multilayer)are comprised in a stack that isfixed vibration-proof on the com-posite fiber platform.

Then the stainless-steel case is her-metically and permanently sealed.The composite fiber platform alsoserves as a base for adaptation toa variety of different outlined elec-trical connecting elements (termi-nals) including custom specificdesigned fixings.

This is a concept that promoteshigh flexibility in designing linkcircuit banks within the speci-fied geometries of IGBT powermodules. Modular lining up ofthe PCCs on a busbar producesthe rated capacitance that isnecessary to ensure the circuitinductance and current han-dling for defined IGBT switch-ing speed and non-oscillatingoperation. Extra decouplingcapacitors, a parallel, low-induc-tance capacitor bank and acomplex busbar design are nolonger needed. The standard-ization and modularity of the

PCC HPSTACK

Section A Section A

Solid contact

zone

Without EPCOS wavy cut

EPCOS wavy cut

Metalization

Metalization

Metalization

Metalization

Metalization

Flame spray area

Film, & film freemargin

Film,& film free margin

Heavy edge

Heavy edge

Flame sprayed contact area

Large effectivecontact area

8EPCOS AG

Technical data

Rated voltage UN [V] (900 to 6000 Vdc), ref. table*)

Rated capacitance Cn [µF] (<10 000 µF, inquire for different ratings), ref. table*)

Tolerance ∆CN [%] ±10% or ±5%

Rated energy WN [Ws] 500 to 3500 Ws

Rated current IN [A] (…300 A); depending on capacitance and terminal

Inductance Lself [nH] 15 to 40 nH

Dielectric loss tan ∂o 2 * 10–4

Dielectric – Polypropylene or polyester (structured)

Rated rms current IN rms [Arms] up to 300 A

Operating temperature range LCT/ [°C] TAMBOPER = –40°C to +85°C(lower/upper category) UCT

Humidity class Hrel [%] Class C; ≤95% mean relative humidity

Max. altitude – [m] 4000 m a.s.l.

Cooling – Natural or forced

Impregnation – NPCB, dry

Mounting regulation – None

Case – Stainless steel, composite fiber platform

Test voltage UT-T [Vdc] 1.5*UNdc, 10 s, RT

UT-C [Vac] 2*Ui + 1000 VAC, 60 s, (min. 2500 VAC)

Peak current IP [A] ≤200 kA

Self-discharge time constant τ [s] RiS *C ≥10 000 s

Failure rate αAQ [h] 300 / 109 h

Expected lifetime tDB(CO) [h] 100.000 h

Standards – IEC 1071-1; NFF-16-101/102; IEC C8

PCC HP

insert

busbar

IGBT

heat sink

*) Note: others than standard values available on request

MKK technology

9EPCOS AG

MKK is based on the proven tech-nology of structured or unstruc-tured polymer films, preferably poly-propylene or polyester, metalizedwith reinforced edge. The alloy metalization (with zincand aluminum as its major con-stituents) and edge enhancementwith extra junctions or cross-profilemetalization, play a significant role in achieving high current han-dling and stable capacitance inhigh operating temperature range. A special film cutting technique(optimized combination of wavyand smooth cuts) produces a maxi-mum effective contact surface for the metal spraying (shooping)or contacting process (windingdesign). This results in exceptionalsurge current capability. The pinch-ing effect on the film edge of thewinding, the cause of contact edgeproblems, is thus demonstrablyeliminated.

Winding techniqueAn optimized winding techniquecreates products of the highestprecision and quality. For reasons of space, flat wind-ings are preferred, in addition tostacked windings, in rectangularcapacitors.

Maintenance andenvironmentThe dry technology and gasimpregnation of self-healing (SH)MKK capacitors are environment-friendly and mean maintenance-free operation throughout capac-itor service life. When it comes to disposal, MKK capacitors gen-erally rate as normal householdrefuse.

Safety (SH, FF)MKK capacitors are self-healingand feature a fuse function (FF)to guard against overcurrent.

1 Dielectric2 Metalized Electrodes3 Material displacing shock wave4 Air gap with metal vapor

5,6 Plasma zone7 Boundary layer between gas phase

dielectric & plasma8 Break down channel9 Gas phase dielectric

10 Zone of displaced metalization & dielectric (insulating area)

x

r1 10

4 2

42

6

6

8 10 1

2 4

245

5

10 101

1

399 7

37 9

30 µm 10 µm

(Combined wavy and smooth cuts)

1 Smooth cut2 Metalized electrode

and edge reinforcedcontact zone

3 Wavy cut4 Free strip5 Partial capacitor6 Free edgea Film thicknessB Segment spacingd Width of current

gatese Distance between

partial capacitorsR Contact radiuss Spacing between

current gatesÜ Cover

A B

B

B

R Re

e

Ü

s

sd

d1

3

1

3

5

cut A – B

1

3

a

a

2

4

6 6

Film design for internal series circuit with structuredmetalization

5

The benefits have become veryapparent since the MKK tech-nology was introduced, and all ofthem feature in PCC HP.

a The very low self-inductance ofthe capacitors allows reductionof circuit inductance.

a Low inductance enhances theperformance of the circuit, cut-ting operating and applicationcosts.

a PCC design guarantees opti-mum adaptation to all semicon-ductor requirements.

a No capacitor bank cross-con-nection and extra decouplingcapacitors are required.

a No configuration mountingrestrictions.

a The maintenance-free PCC-HPrequires no safety precautions,further reducing operating andproduction costs.

a PCC-HP design advantages cut dimensions, engineeringvolume and weight of theapplication.

a Competitive advantage for theuser through high availability,long lifetime and no tempera-ture depending capacitance drift.

in any position

Reasons for choosing PCC HP

BatteryInverter

G

Engine M

GearboxGB

design in performance

Design features

10 EPCOS AG

PCC Power ranges

Power [MW] Voltage [V] Preferred

0,20 > P < 16 > 600 V High-power-PCC HP

0,01 < P < 0,2 < 600 V Low-power-PCC LP*)

PCC-HP connectors

Contact Current handling/ terminal [A] Contact interconnection

Strap terminal 125 Busbar

Screw terminal M16/M12 200/100 Busbar

Multicontact (MC) 100 Busbar

PCC-HP designs are available with various selectable connectors (terminals & fixings) to provide for solutions and applications an optimal connection.

PCC-HP standard dimensions (L =367 x W=195 x H = … mm)

Nominal voltage [V] height [mm]

80 145 256

Nominal capacitance [µF]

900 1380 3460 6950

1050 1150 3000 6000

1200 1000 2500 5000

1500 640 1600 3200

1800 440 1100 2200

2000 360 900 1800

3000 150 390 780

PCC-HP standard dimensions are graduated according to rated operating voltage (contact wire voltage) for tractionapplications.

*) PCC LP: Low Power Capacitors for Drive SystemsEPC:26006-7400

cost down… cost down…

Design hints

11EPCOS AG

New designs of drive systems Low-cost safetyThe PCC is an outspoken tech-nical alternative solution in thealuminum electrolytic capacitor’sapplication area.

The costs of safety devices, like oil-leakage precautions, sensorswith monitoring aids, fire andexplosion protection, regularmaintenance, etc, is not requiredanymore if dry-technology PCCsare selected for new designs.

The PCC HP’s feature of no mount-ing restrictions – even upsidedown – contributes to achieve thesystem design goal with smallestdimensions and lowest weight.

The long maintenance-free life-time of PCCs (no completereplacement after three to fiveyears) is another important cost-saving factor.

PCC-HP scale drawing

KLK1679-6

L

53

H

W

15

195

211

130 130

367

Firm label

M6

170

Thread depth 8 mm

W

Firm label

53

H

56

M6

200

M6

170

Thread depth 8 mm

L

Connecting-lugs Multicontact-MC

(Insert)(Insert)

Fixing hinge

Mature technology proven in the field

12EPCOS AG

New control conceptsThese allow substantially higherripple of the link voltage withoutdrawbacks where inverter perfor-mance is concerned. This meansthat the designer can put smallerbank capacitances into the linkcircuit, supporting the penetrationof metalized, self-healing drypower capacitors into what wasonce a domain of aluminumelectrolytics.

TrendThe trend in power electronicspoints to higher power and morecompact components. The newlydeveloped PCC technology is anoptimum match for these require-ments in IGBT applications, forindustrial, automotive and tractioninverters. Follow-on PCC devel-opment is focusing on the pro-duction and metalization of high-grade, self-healing polymer films,with the aim of further enhancingcurrent handling and electricalfield strength during operation.

mating all… mating all…

Current [kA]10-1 100 101

Volt

age

[kV

]

10

1

PCC LP PCC HP

2 kV2.5 kV 3.3 kV

6.5 kV

IGBT

GTO

IPM

GCT

Electric PowerSteel mill, etc.

Industrial, HEV

LP IGBT

HV IGBT

IGBT Insulated Gate Bi-polar ThyristorGCT Gate Commutated Turn-off ThyristorGTO Gate Turn-off ThyristorIPM Intelligent Power Module

13 EPCOS AG

~=

3~

G

~=

=~

=~

DC-Link PCC LP

EC (Energy Converter/Puffer)

3~

M/G

CNTRL Bus

CNTRL / Energy Management

DC-Link PCCDiesel Engine

Inverter Converter

Inverter

Converter

=~ M1

3~

M2

Gear Box

Diesel Engine

3 Phase User-NetworkGrid

CNTRL Bus

CNTRL CPU

Power line switch

Battery

Power bus switch

Solar

Wind

Hydro

OtherPower Heat exchange

GB

EC

PCC HPDC-Link

3~Transformer

~= =

~Rear-EndInverter

Front-EndConverter

15 kVAC 16 2/3 HzAC-Traction System

ASMASM

PCC HPDC-Link

~=

DC/ACInverter Unit

ProtectionCircuit

1450 VDC

DC-Traction System

3~

M3~

M

M 3~

M 3~

M 3~

M 3~

~= =

~

~= =

~

L-Filter

DC-Link PCC

EP (Energy Converter/Puffer)

3~

M/GCNTRL Bus

CNTRL / Energy Management

DC-Link PCC

3~

GDiesel Engine

Inverter Converter

Inverter Converter

Power Wheel

PW

Applications

)4'37 %+

Herausgegeben von EPCOS AG, Marketing KommunikationPostfach 801709, 81617 München, DEUTSCHLAND☎ (089) 636-09, FAX (089) 636-2 2689 EPCOS AG 2000. Alle Rechte vorbehalten. Vervielfältigung, Veröffentlichung, Verbreitung und Verwertung dieserBroschüre und ihres Inhalts ohne ausdrückliche Genehmigung der EPCOS AG nicht gestattet.Mit den Angaben in dieser Broschüre werden die Bauelemente spezifiziert, keine Eigenschaften zugesichert. Bestellungenunterliegen den vom ZVEI empfohlenen Allgemeinen Lieferbedingungen für Erzeugnisse und Leistungen derElektroindustrie, soweit nichts anderes vereinbart wird. Diese Broschüre ersetzt die vorige Ausgabe. Fragen über Technik,Preise und Liefermöglichkeiten richten Sie bitte an den Ihnen nächstgelegenen Vertrieb der EPCOS AG oder an unsereVertriebsgesellschaften im Ausland. Bauelemente können aufgrund technischer Erfordernisse Gefahrstoffe enthalten.Auskünfte darüber bitten wir unter Angabe des betreffenden Typs ebenfalls über die zuständige Vertriebsgesellschafteinzuholen.

Published by EPCOS AG, Marketing CommunicationsP.O.B. 801709, 81617 Munich, GERMANY☎ ++49 89 636-09, FAX (089) 636-2 2689 EPCOS AG 2000. All Rights Reserved. Reproduction, publication and dissemination of this brochure and the informationcontained therein without EPCOS’ prior express consent is prohibited.The information contained in this brochure describes the type of component and shall not be considered as guaranteedcharacteristics. Purchase orders are subject to the General Conditions for the Supply of Products and Services of theElectrical and Electronics Industry recommended by the ZVEI (German Electrical and Electronic Manufacturers’Association), unless otherwise agreed. This brochure replaces the previous edition. For questions on technology, prices anddelivery please contact the Sales Offices of EPCOS AG or the international Representatives. Due to technical requirementscomponents may contain dangerous substances. For information on the type in question please also contact one of ourSales Offices.