Capabilities

V is h ay I n t e rt e c h n o l o g y, I n c .
I
INNOVAT
AND TEC
O L OGY
Power Application Capabilities
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Capacitors - Aluminum Electrolytic
Aluminum Electrolytic Capacitors
in Power Applications
Power Applications
•
•
•
•
•
Motor Drives
Solar Inverters
Traction in trains or rolling stock
Uninterruptible Power Supply (UPS)
Pulsed Power
Resources
• For technical questions contact [email protected]
• Sales Contacts: http://www.vishay.com/doc?99914
One of the World’s Largest Manufacturers of
Discrete Semiconductors and Passive Components
Capabilities
1/11
VMN-PL0453-1204
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SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Motor Drives
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Capacitors - Aluminum Electrolytic
Introduction to the
Application
Motor drives are used to control the speed of
various motors in all kinds of systems, from
the small pumps and motors in household
washing machines and central heating and
air-conditioning systems to the large motors
found in industrial machinery.
Selecting the Best Capacitor for
Your Motor Drive Application
Aluminum capacitors are often used as
DC link capacitors in motor drives, both in
1-phase and 3-phase designs. The aluminum
capacitor is used as an energy buffer to
ensure stable operation of the switch mode inverter driving the motor. The aluminum capacitor also functions as a filter to
prevent high-frequency components from the switch mode inverter from polluting the mains voltage.
The key selection criterion for the aluminum capacitor is the required ripple current. The ripple current consists of two
components, a low-frequency ripple (50 Hz to 200 Hz) from the input and a high-frequency component from the inverter,
typically 8 kHz to 20 kHz.
To maximize its operating life, the aluminum capacitor should be located on the coolest possible area of the PCB. Forced
cooling or mounting of the capacitor on a heat sink may increase device lifetime by as much as fourfold, especially in
combination with the extended cathode construction inside the aluminum capacitor.
It is advisable to specify a minimum capacitance to ensure stable operation of the drive. The capacitor’s inductance (ESL)
may contribute to the occurrence of transient signals. ESL values below 13 nH can be reached in large case size screw
terminal devices.
Series and parallel connections are common techniques used to allow aluminum capacitors to operate at voltages up to
1200 V. Care should be taken to balance the intermediate voltage between the capacitors.
Our focus series
For PCB mounting we offer 2-pin, 3-pin, or 4-pin snap-in capacitors with long life and high current ratings, some with
an internal extended cathode design, enabling fast transfer of heat outside of the capacitor body. For larger industrial
applications, large can screw terminal aluminum capacitors are available, all with extended cathode construction.
Main series for PCB mounting
Main series for high-power industrial drives
159 PUL-SI (Standard, 105 °C)
102 PHR-ST (Long life, high ripple current, 85 °C)
193 PUR-SI (Low ESR, high ripple current, 105 °C)
104 PHL-ST (High ripple current, 105 °C)
198 PHR-SI (High ripple current,
extreme long life, 85 °C)
096 PLL-4TSI (4-Terminal, 85 °C)
Capabilities
2/11
VMN-PL0453-1204
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SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Motor Drives
N
HN
aluminum electrolytic capacitors
O
19
62-2012
2 Examples of the 198 PHR-SI series:
Capacitors - Aluminum Electrolytic
Electrical Data and Ordering Information
Ordering Code
MAL2198…
UR
(V)
CR
100
Hz
(μF)
Nominal
Case Size
ØDxL
(mm)
IR
100 Hz
85 °C
(A)
IL1
1
min
(mA)
IL5
5 min
(mA)
Typ
ESR
100
Hz
(mΩ)
Max
ESR
100
Hz
(mΩ)
Typ Z
10 kHz
(mΩ)
Max Z
10 kHz
(mΩ)
2-Term
3-Term
400
470
35 x 45
2.72
1132
380
129
203
80
153
36471E3
16471E3
450
560
35 x 60
3.10
1516
508
100
171
60
120
57561E3
77561E3
3 Examples of the 102 PHR-ST series:
Electrical Data and Ordering Information for 102 Series
UR
(V)
IR
ESR
Z
IL5
CR
Nominal
Max
Max
100 Hz
100 Hz Case Size Ø D
5 min
100 Hz 20 kHz
85°C
(μF)
x L (mm)
(mA)
(mΩ)
(mΩ)
(A)
High Post M5 Disc
ST
Ordering
Code
MAL2102…
High Current M6 Disc
ST Bolt Nut
ST
Ordering
Ordering
Code
Code
MAL2102… MAL2102…
ST Bolt Nut
Ordering
Code
MAL2102…
250
4700
76 x 105
15.3
2.35
29
19
23472E3
63472E3
43472E3
83472E3
400
3300
76 x 105
13.4
2.64
40
27
26332E3
66332E3
46332E3
86332E3
450
5600
76 x 146
17.3
5.04
23
15
17562E3
57562E3
37562E3
77562E3
Figure 1: A typical block diagram of the motor drive
3-Phase IGBT Power Stage
3-Phase
Filter
Current
Compensated
Choke
DC Link
Rectifier
Bridge
Induction Motor
3-Phase
and
X-Capacitors
and
Y-Capacitors
Film Capacitors
Y-Capacitors
Capabilities
DC Link Capacitor
3/11
VMN-PL0453-1204
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SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Solar Inverters
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Capacitors - Aluminum Electrolytic
Introduction to the
Application
Solar photovoltaic applications have shown
strong growth globally since 2005. Solar
inverters are used to efficiently convert the
DC power generated by the solar panels
into useable AC power for the electricity grid
or household systems. Solar inverters are
available with a wide range of power ratings.
Depending on the power range of the total
system, single-household inverters range up
to 3 kW, coupled string inverters up to 10 kW,
and large central inverters up to 500 kW.
Selecting the Best Capacitor
for your Solar Inverter
Power capacitors are used in solar inverters as DC-link capacitors, creating enough DC energy to enable smooth
operation of the DC/AC converter. Depending on the power range, maximum allowable voltage, available space, lifetime
requirements, and cost of design, either aluminum or power film capacitors may be used. Both types are available from
Vishay.
The Right Aluminum Capacitor for the Job Depends on Two Main
Operating Conditions:
Normal operation: In this condition, the Maximum Power Point (MPP) tracking system will maintain a reduced voltage
on the capacitors in combination with rather high ripple currents and elevated temperatures inside the inverter housing.
Capacitor lifetime is mainly determined by the applied ripple current and ambient temperature in normal operation mode.
Off-line operation: In this mode, the solar system is disconnected from the grid, and the voltage on the capacitor rises to
the maximum output voltage of the solar cells. Under this condition, there is no ripple current applied on the capacitor and
the ambient temperature in the inverter housing is reduced. This operation mode determines the maximum voltage the
capacitor is designed for under no-load or low-load conditions at moderate temperatures inside the housing.
Typical maximum output voltages for solar panels are 600 V, 800 V, and 1000 V. A pair of aluminum capacitors connected
in series is needed to cover this voltage range. Care should be taken to balance the voltage over the series connection of
the aluminum capacitors. Balancing the voltage on the center point between the two series capacitors is vital, but could
cause significant efficiency losses caused by using e.g. balancing resistors.
Further important parameters for the aluminum capacitor include the total capacitance, which should be high enough to
maintain smooth operation of the converter.
Our Focus Series
For PCB mounting Vishay offers 2-, 3-, and 4-terminal snap-in products in case sizes ranging from 30 mm x 40 mm to
45 mm x100 mm. For central inverters we offer screw terminal series in case sizes up to 90 mm x 220 mm.
Capabilities
4/11
VMN-PL0453-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Solar Inverters
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Capacitors - Aluminum Electrolytic
Design examples for solar applications:
Series
Cap
(μF)
Size D*H
(mm)
UR
(V)
UC
(V)
IR (100 Hz)
(A)
Lifetime
(UR, 85 °C)
Lifetime
(UC, IR, 105 °C)
193 PUR-SI
330
30 x 50
500
400
2.3
2 000 hrs
10 000 hrs
157 PUM-SI
680
35 x 60
500
420
3.2
1 000 hrs
7 000 hrs
095 PLL-4TSI
1000
45 x 70
500
450
3.8
5 000 hrs
5 000 hrs
159 PUL-SI
1200
35 x 80
320
-
5.1
-
7 000 hrs
104 PHL-ST
4700
76 x 175
500
450
12.1
20 000 hrs
10 000 hrs
Figure 2: a typical block diagram of a solar inverter
Step-up converter
UDC +
UDC –
EMC
filter
Bridge circuit
Fault current
and earth
leakage
monitoring
Mains relay
EMC
Filter
L
N
PE
DC Link Capacitors
LC display
Capabilities
Control unit with digital signal processor (DSP)
5/11
PC interface
VMN-PL0453-1204
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V is h ay I n t e rt e c h n o l o g y, I n c .
I
INNOVAT
AND TEC
O L OGY
for Traction Applications
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Introduction to the Application
Capacitors - Aluminum Electrolytic
Traction is a blanket term for applications in trains or “rolling
stock.” Both the electrical propulsion systems as well as the
electrical systems supporting the brakes, lighting, power
supply are focus area included in this application category.
Selecting the Best Capacitor for your
Traction Application
Aluminum electrolytic capacitors are used in two main
applications in traction:
• As DC link capacitors in traction drives used to control
the speed of large electrical motors in rolling stock
• As DC link capacitors in auxiliary power supplies in
rolling stock
In both fields the aluminum capacitor is used as an energy
buffer to ensure stable operation of the switch mode inverter
driving the motor or auxiliary power circuit. The aluminum
capacitor also functions as a filter to prevent high-frequency
components in the switch mode alternator from disturbing
the mains input.
The key selection criterion for the aluminum capacitor is the needed ripple current, which corresponds to the 8 kHz to 20
kHz high-frequency ripple currents generated by the inverter.
To maximize its operating life, the aluminum capacitor should be located on the coolest possible area of the PCB. Forced
cooling or mounting of the cap on a heat sink may increase component lifetime, especially in combination with the
extended cathode construction inside the aluminum capacitor.
It is advisable to specify a minimum capacitance to ensure stable operation of the drive. The capacitor’s inductance (ESL)
may contribute to the occurrence of transient signals. ESL values below 13 nH can be reached in large case size screw
terminal devices.
Both series and parallel connections are commonly used with aluminum capacitors as the voltages in rolling stock may
well reach up to 1200 V. In such cases three aluminum capacitors can be used in series. Care should be taken to balance
the intermediate voltage between the capacitors.
For higher voltage ranges and heavy duty applications, power film resistors, also available from Vishay, are the best option.
Our Focus Series
For traction we offer large can screw terminal aluminum capacitors including models with an extended cathode
construction for optimized cooling.
Main series for high-power industrial drives
102 PHR-ST (Long life, high ripple current, 85 °C)
104 PHL-ST (High ripple current, 105 °C)
Capabilities
6/11
VMN-PL0453-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
for Traction Applications
O L OGY
INNOVAT
I
aluminum electrolytic capacitors
N
HN
O
19
62-2012
Two examples of the 102 PHR-ST series:
Capacitors - Aluminum Electrolytic
Electrical Data and Ordering Information for 102 Series; 85 °C - 10 000 hrs
UR
(V)
CR
100
Hz
(μF)
Nominal
Case Size
ØDxL
(mm)
IR
100
Hz 85
°C (A)
IL5
5
Min
(mA)
ESR
Max
100
Hz
(mΩ)
Z
Max
20 kHz
(mΩ)
350
15
000
90 x 220
31.2
10.5
10
400
10
000
76 x 220
22.1
8.0
14
HIGH POST M5 DISC
HIGH CURRENT M6
DISC
ST
Ordering
Code
MAL2102…
ST Bolt Nut
Ordering
Code
MAL2102…
ST
Ordering
Code
MAL2102…
ST Bolt Nut
Ordering
Code
MAL2102…
8
-
-
45153E3
85153E3
11
16103E3
56103E3
36103E3
76103E3
Two examples of the 104 PHL-ST series:
Electrical Data and Ordering Information for 104 Series; 105 °C - 5 000 hrs
CR
UR
100 Hz
(V)
(μF)
Nominal
Case Size
ØDxL
(mm)
IR
ESR
Z
IL5
Max
Max
100 Hz
5 Min
100 Hz 20 kHz
85°C
(mA)
(mΩ)
(mΩ)
(A)
High Post M5 Disc
ST
Ordering
Code
MAL2104…
High Current M6 Disc
ST Bolt Nut
ST
Ordering
Ordering
Code
Code
MAL2104… MAL2104…
ST Bolt Nut
Ordering
Code
MAL2104…
350 15 000
90 x 220
25.6
10.5
13
12
-
-
45153E3
85153E3
400 10 000
90 x 220
22.1
8.0
17
14
-
-
46103E3
86103E3
Figure 3: a typical block diagram of the application
3-Phase IGBT Power Stage
3-Phase
Filter
Current
Compensated
Choke
DC Link
Rectifier
Bridge
Induction Motor
3-Phase
and
X-Capacitors
and
Y-Capacitors
Film Capacitors
Y-Capacitors
Capabilities
DC Link Capacitor
7/11
VMN-PL0453-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Uninterruptible Power Supply (UPS) Applications
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Introduction to the Application
Uninterruptible power supplies (UPS) are used to maintain
power during short power outages. UPS are available in
off-line and on-line types, and also offer varying power levels
and maximum operating times for interruption coverage.
Capacitors - Aluminum Electrolytic
Selecting the Best Capacitor for your UPS
Aluminum capacitors are often used as DC-link capacitors
in UPS, both in on-line as well in off-line systems. The
aluminum capacitor is used as an energy buffer to ensure
stable operation of the output DC/AC converter of the UPS
system. The aluminum capacitor also functions as a filter
to prevent high-frequency components in the switch mode
alternator from disturbing the mains input.
The key selection criterion for the aluminum capacitor is the
needed ripple current. The ripple current consists of two
components, a low-frequency ripple (50 Hz to 200 Hz) from the input and a high-frequency component from the DC/AC
converter, typically 10 kHz to 40 kHz.
To maximize its operating life, the aluminum capacitor should be located on the coolest possible area of the PCB. Forced
air-cooling will reduce the overall temperature of the capacitor, enabling larger ripple current capabilities or longer life. It is
advisable to specify a minimum capacitance to ensure stable operation of the drive.
Series and parallel connections are used as common techniques to allow aluminum capacitors to operate at voltages up
to 1200 V. Care should be taken to balance the intermediate voltage between the series connected capacitors, without
reducing the efficiency of the UPS system significantly.
Our Focus Series
For PCB mounting we offer 2-pin, 3-pin or 4-pin snap-in capacitors with long life and high current ratings, all with internal
extended cathode design, enabling fast transfer of heat outside of the capacitor body. For larger industrial applications,
large can screw terminal aluminum capacitors, including the extended cathode construction are available.
Main series for PCB mounting
Main series for high-power industrial drives
159 PUL-SI (Standard, 105 °C)
102 PHR-ST (Long life, high ripple current, 85 °C)
193 PUR-SI (Low ESR, high ripple current, 105 °C)
104 PHL-ST (High ripple current, 105 °C)
198 PHR-SI (High ripple current, extreme long life, 85 °C)
096 PLL-4TSI (4-Terminal, 85 °C)
Two examples of the 198 PHR-SI series:
Electrical Data and Ordering Information
Ordering Code
MAL2198…
UR
(V)
CR
100
Hz
(μF)
Nominal
Case Size
ØDxL
(mm)
IR
100
Hz 85
°C (A)
IL1
1
min
(mA)
IL5
5 min
(mA)
Typ
ESR
100
Hz
(mΩ)
Max
ESR
100
Hz
(mΩ)
Typ Z
10 kHz
(mΩ)
Max Z
10 kHz
(mΩ)
2-Term
3-Trem
400
470
35 x 45
2.72
1132
380
129
203
80
153
36471E3
16471E3
450
560
35 x 60
3.10
1516
508
100
171
60
120
57561E3
77561E3
Capabilities
8/11
VMN-PL0453-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Uninterruptible Power Supply (UPS) Applications
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Three examples of the 102 PHR-ST series:
Capacitors - Aluminum Electrolytic
Electrical Data and Ordering Information for 102 Series
IR
ESR
Z
IL5
Max
Max
100 Hz
5 Min
100 Hz 20 kHz
85°C
(mA)
(mΩ)
(mΩ)
(A)
High Post M5 Disc
High Current M6 Disc
UR
(V)
CR
100 Hz
(μF)
Nominal
Case Size
ØDxL
(mm)
250
4700
76 x 105
15.3
2.35
29
19
23472E3
63472E3
43472E3
83472E3
400
3300
76 x 105
13.4
2.64
40
27
26332E3
66332E3
46332E3
86332E3
450
5600
76 x 146
17.3
5.04
23
15
17562E3
57562E3
37562E3
77562E3
ST
Ordering
Code
MAL2102…
ST Bolt Nut
ST
Ordering
Ordering
Code
Code
MAL2102… MAL2102…
ST Bolt Nut
Ordering
Code
MAL2102…
Figure 4: a typical block diagram of an uninterruptible power supply
Input Filter
AC/DC
Converter
DC Bank
DC/AC
Converter
Transformer
and filter
Output
DC Link Capacitor
Battery
Manager
Capabilities
Battery
9/11
VMN-PL0453-1204
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SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
AND TEC
I
INNOVAT
O L OGY
for Pulsed Power Applications
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Introduction to the Application
Capacitors - Aluminum Electrolytic
Pulsed power applications are those in which the
consumption of electrical energy takes the form of
distinct pulses rather than having a continuous profile.
Good examples of pulsed power applications are welding
equipment, X-rays, and high-frequency plasma torches.
Selecting the Best Capacitor for your
Pulsed Power Application
Aluminum capacitors are often used as an energy buffer
that is capable of generating an electrical energy boost to
operate the primary function of the application.
The main parameter in this application is the minimum capacitance of the aluminum capacitor.
This capacitance defines the magnitude of the electrical energy boost the device can generate.
Of secondary importance is the inductance of the capacitor (ESL), for which large values may increase the occurrence of
transient signals. Values of ESL below 13 nH for large case size screw terminals are available.
Care should be given to the voltage drop over the capacitors during the discharge cycle.
A full discharge would require design adaptations in the capacitor, whereas discharges in the range of 30 % to 40 % of the
maximum operating voltage can prolong capacitor lifetime in the application significantly.
Our Focus Series
For PCB mounting, we offer 2-pin, 3-pin, or 4-pin snap-in capacitors with high specific capacitance, long life, and an
internal extended cathode design. For high-voltage industrial applications such as professional welding, HF plasma
torches, and X-ray equipment, we recommend our Large Can Screw Terminal Aluminum Capacitors, including the
extended cathode construction.
Main series for PCB mounting
Main series for high-power industrial drives
157 PUM-SI (Standard, 85 °C)
102 PHR-ST (Long life, high ripple current, 85 °C)
159 PUL-SI (Standard, 105 °C)
500 PGP (High C/V, 85 °C)
193 PUR-SI (Low ESR, high ripple current, 105 °C)
096 PLL-4TSI (4-Terminal, 85 °C)
Design examples for pulsed power applications:
Series
Style
UR (V)
Cap (μF)
Size D*H (mm)
Useful life
157 PUM-SI
Snap-In
300
1 000
35 x 50
5 000 h at 85 °C
159 PUL-SI
Snap-In
450
560
35 x 60
5 000 h at 105 °C
102 PHR-ST
Screw Terminal
350
15 000
90 x 220
10 000 h at 85 °C
102 PHR-ST
Screw Terminal
400
10 000
76 x 220
10 000 h at 85 °C
500 PGP-ST
Screw Terminal
450
16 000
90 x 220
2 000 h at 85 °C
Capabilities
10/11
VMN-PL0453-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000
V is h ay I n t e rt e c h n o l o g y, I n c .
I
INNOVAT
AND TEC
O L OGY
for Pulsed Power Applications
N
HN
aluminum electrolytic capacitors
O
19
62-2012
Figure 5: Block diagram of a typical pulsed power application
Power
Rectifier
DC buffer cap
DC/DC
Converter
Mains
=
=
Capacitors - Aluminum Electrolytic
EMC
filter
=
~
DC link capacitor
Capabilities
11/11
VMN-PL0453-1204
This document is subject to change without notice. THE PRODUCTS DESCRIBED HEREIN AND THIS DOCUMENT ARE SUBJECT TO
SPECIFIC DISCLAIMERS, SET FORTH AT www.vishay.com/doc?91000