Medium Power Film Capacitors FFLI 800V to 1400Vdc (RoHS Compliant) DC FILTERING The FFLI series is specifically designed for DC filtering applications such as DC link. This range offers solutions for voltage from 800V up to 1400V. The Controlled Self Healing Technology, essential to ensure a safe and reliable behaviour, is achieved using a fully dry solution with polypropylene metallized and segmented film. Standard designs proposed in this catalogue are covering a wide range of voltage and capacitance values. In case of specific requirements about shape and performances, please feel free to contact your local AVX representative. PACKAGING MATERIAL Aluminium cylindrical case filled polyurethane resin. Self extinguishing polyurethane resin (V0 : in accordance with UL94; M2F1: in accordance with NF F 16-101) Self extinguishing plastic cover (V0 : in accordance with UL94) RoHS components M6/10 Female connections or M8/20 Male connections STANDARDS IEC 61071: Power electronic capacitors IEC 61881: Railway applications, rolling stock equipment, capacitors for power electronics IEC 60068-2: Environmental testing IEC 61373: Shock and vibrations UL 94: Fire requirements HOW TO ORDER FFLI 6 L 0337 K –– Series Dielectric 6 = Polypropylene Voltage Code B = 800V L = 1000V U = 1150V Q = 1400V Capacitance EIA Code Capacitance Tolerances K = ±10% Terminal Code – – = Male Threaded JE = Female Threaded CHARACTERISTICS DEFINITIONS Cn (μF) capacitance Un (V) rated DC voltage Uw (V) working voltage Ur (V) Ls (nH) Rs (mΩ) ripple voltage parasitic inductance series resistance Irms (A) RMS current θamb (°C) cooling air temperature θHS (°C) hot spot temperature I²t (A²s) integral of action 30 ■ JUNE 2015 nominal value of the capacitance measured at θamb = 25 ± 10°C maximum operating peak voltage of either polarity (non-reversing type waveform), for which the capacitor has been designed for continuous operation value of the maximum operating recurrent voltage for a given hot spot temperature and an expected lifetime peak-to-peak alternating component of the unidirectional voltage capacitor series self-inductance capacitor series resistance due to galvanic circuit RMS current value for continuous operation under natural convection generating 40°C overheating temperature of the cooling air measured at the hottest position of the capacitor, under steady-state conditions, midway between two units Capacitance range Cn Tolerance on Cn Rated DC voltage Un Lifetime at Un and 65°C hot-spot temperature and ΔC / C < 2% Parasitic inductance Ls Maximum rms current Irms Test voltage between terminals @ 25°C Test voltage between terminals and Case @ 25°C Dielectric NOTE If only one unit is involved, it is the temperature measured at a point approximately 0.1 m away from the capacitor container and at two-thirds of the height from its base Climatic Category highest temperature obtained inside the case of the capacitor in thermal equilibrium maximum repetitive integral of action that galvanic circuit is able to withstand Working temperature (according to the power dissipated) Storage temperature Calorific value -40°C / +85°C 40 MJ/kg 105μF to 3000μF ±10% 800 to 1400V 100,000h 35 to 60nH up to 112Arms 1.5 x Un for 10s 4kVrms @ 50Hz for 10s polypropylene 40 / 95 / 56 (IEC 60068) -40°C / +95°C Medium Power Film Capacitors FFLI 800V to 1400Vdc (RoHS Compliant) DC FILTERING LIFETIME EXPECTANCY VS HOT SPOT TEMPERATURE AND VOLTAGE 1.5 1.4 1.3 Uw/Un 1.2 1.1 1 θHS = 55ºC θHS = 65ºC θHS = 75ºC θHS = 85ºC θHS = 95ºC 0.9 0.8 0.7 100 1,000 10,000 100,000 1,000,000 Lifetime Expectancy (hours) HOW TO CHOSE THE RIGHT CAPACITOR The capacitor lifetime depends on the working voltage and the hot spot temperature. Our caps are designed to meet 100000 hours lifetime at rated voltage and 65°C hot spot temperature. In accordance with operating conditions, please calculate the hot spot temperature and deduce from this calculation if the obtained lifetime can suit the application. Un Uw Ur Voltage 1. From the tables, select a capacitor with required capacitance Cn and voltage Un. Calculate the maximum ripple voltage allowed for the selected cap: Urmax = 0.2Un If Ur>Urmax, select a capacitor with higher rated voltage Make sure Irms application < Irms table Copy out: • serial resistance (Rs): see table of values • thermal resistances Rth 1/f Time 2. Hot spot temperature calculation Total losses are calculated as follow: Pt=Pj+Pd Joule losses: Pj = Rs x Irms² Dielectric losses: Pd = Q x tgδ0 with • Q(reactive power) = Irms2 for a sinusoidal waveform ––––– C Rth HS AMB • tgδ0 = 2 x 10-4 (dielectric losses of polypropylene) Hot spot temperature will be: HS = amb + (Pj + Pd) x Rth HS absolute maximum is 95°C If temperature is higher than 95°C, come back to #1 and start again with another selection. Rth: thermal resistance between case and ambient air JUNE 2015 ■ 31 Medium Power Film Capacitors FFLI 800V to 1400Vdc (RoHS Compliant) 3. Refer to the curve and deduce the lifetime vs Uw/Un ratio 1.4 θHS = 65ºC 1.3 1.2 Uw/Un DC FILTERING 1.5 eg: rated voltage 1000V working voltage 1050V ρ = 1.05 ⇒ lifetime 50,000 hours @ 65°C hot spot temperature Please, find a calculation form at the end of the catalog 1.1 1.05 1 0.9 0.8 0.7 100 1,000 10,000 1,000,000 50,000 Lifetime Expectancy (hours) MTBF CALCULATION Based on Return Of Experience from the field of more than 30 years, we have established the following relation. The failure rate λB depends on hot spot temperature θHS and charge ratio ρ. ρ = Uw/Un ( ( ) ) in failures/hour GENERAL FAILURE RATE λ=λB x πQ x πB x πE failures/hour • πQ, πB and πE see following tables Qualification Product qualified on IEC61071 and internal qualification Product qualified on IEC61071 Product answering on another norm Product without qualification Qualification factor πQ 1 2 5 15 Environment On On On On On ground (good conditions) ground (fixed materials) ground (on board) ship plane Environment factor πE 1 2 4 9 15 Environment Favorable Unfavourable Environment factor πB 1 5 MEAN TIME BETWEEN FAILURE (MTBF) MTBF = 1/λ hours SURVIVAL FUNCTION N = N0 x exp (-λt) N is the number of pieces still working after t hours. N0 is the number of pieces at the origin (t = 0) FAILURE MODE Main failure mode due to AVX’s Controlled Self-Healing Technology is only losses of capacitance. Thanks to Controlled Self-Healing solution to interrupt self-healing process in order to prevent avalanche effect due to polypropylene molecular cracking producing gas and potential explosion in confined box for none Controlled Self-Healing capacitors. 32 ■ JUNE 2015 Medium Power Film Capacitors FFLI 800V to 1400Vdc (RoHS Compliant) FEMALE TERMINALS MALE TERMINALS A±1 A±1 5±0.5 DC FILTERING DIMENSIONS 3.5 5±0.5 2.5 3.5 2.5 Hc Hc UL94 V-0 Plastic Cover AVX TPC UL94 V-0 Plastic Cover AVX TPC H±2 H±2 Aluminium Case Aluminium Case M12x16 M12x16 D±2 D±2 UL94 V-0 Resin Filling UL94 V-0 Resin Filling M6x10 40 M8x20 40 Dt D (mm) A (mm) Dt (mm) Hc (mm) 75 32 12 30 85 32 12 30 100 116 50 50 15 15 40 40 D (mm) 75 85 100 116 Dt M6 M8 M12 Distance terminal to terminal (mm) creepage clearance 40 19 40 19 55 34 55 34 Max Torque (Nm) 4.5 8.5 15 Distance terminal to case (mm) creepage clearance 47 45 52 50 59 57 67 65 MECHANICAL MOUNTING Capacitors enclosure presents a M12 x 16 bolt in order to fix the capacitor. Over height (H) more than 1.5 x D (diameter of tube), we recommend to clamp (constraint < 35daN), just below the plastic cover, the capacitor in order to limit oscillations in case of potential Shock&Vibration stress. JUNE 2015 ■ 33 Medium Power Film Capacitors FFLI 800V to 1400Vdc (RoHS Compliant) DC FILTERING RATINGS AND PART NUMBER REFERENCE Part Number Capacitance (μF) D H FFLI6B0297K** FFLI6B0397K** FFLI6B0507K** FFLI6B0687K** FFLI6B0817K** FFLI6B1007K** FFLI6B1207K** FFLI6B1357K** FFLI6B1607K** FFLI6B1907K** FFLI6B2407K** FFLI6B3007K** 290 390 500 680 810 1000 1200 1350 1600 1900 2400 3000 75 85 75 85 85 100 100 116 116 116 116 116 105 105 155 155 180 155 180 155 180 240 290 340 FFLI6L0197K** FFLI6L0267K** FFLI6L0337K** FFLI6L0457K** FFLI6L0547K** FFLI6L0657K** FFLI6L0787K** FFLI6L0907K** FFLI6L1107K** FFLI6L1307K** FFLI6L1607K** FFLI6L2007K** 190 260 330 450 540 650 780 900 1100 1300 1600 2000 75 85 75 85 85 100 100 116 116 116 116 116 105 105 155 155 180 155 180 155 180 240 290 340 FFLI6U0157K** FFLI6U0207K** FFLI6U0267K** FFLI6U0357K** FFLI6U0437K** FFLI6U0537K** FFLI6U0637K** FFLI6U0727K** FFLI6U0867K** FFLI6U1007K** FFLI6U1307K** FFLI6U1607K** 150 200 260 350 430 530 630 720 860 1000 1300 1600 75 85 75 85 85 100 100 116 116 116 116 116 105 105 155 155 180 155 180 155 180 240 290 340 FFLI6Q1056K** FFLI6Q0147K** FFLI6Q1856K** FFLI6Q0257K** FFLI6Q0307K** FFLI6Q0367K** FFLI6Q0447K** FFLI6Q0507K** FFLI6Q0607K** FFLI6Q0707K** FFLI6Q0907K** FFLI6Q1107K** 105 140 185 250 300 360 440 500 600 700 900 1100 75 85 75 85 85 100 100 116 116 116 116 116 105 105 155 155 180 155 180 155 180 240 290 340 Irms (A) I2t (A2s) Typical LS (nH) Typical RS (mΩ) Rth (°C/W) Typical Weight (g) 13 24 13 24 24 52 52 95 95 320 320 320 35 35 50 50 60 50 60 50 60 40 50 60 3.1 2.3 4.1 3.1 3.5 2.2 2.5 1.7 2.0 1.1 1.2 1.4 4.5 4.0 4.0 3.7 3.4 3.4 3.3 3.2 3.1 2.9 2.7 2.4 600 700 850 1100 1300 1500 1800 2000 2400 3200 3900 4500 8 16 8 16 16 33 33 66 66 210 210 210 35 35 50 50 60 50 60 50 60 40 50 60 3.7 2.8 4.9 3.7 4.2 2.7 3.0 2.0 2.3 1.2 1.4 1.6 4.5 4.0 4.0 3.7 3.4 3.4 3.3 3.2 3.1 2.9 2.7 2.4 600 700 850 1100 1300 1500 1800 2000 2400 3200 3900 4500 7 12 7 12 12 27 27 51 51 160 160 160 35 35 50 50 60 50 60 50 60 40 50 60 4.2 3.2 5.6 4.2 4.7 2.9 3.3 2.2 2.5 1.4 1.5 1.7 4.5 4.0 4.0 3.7 3.4 3.4 3.3 3.2 3.1 2.9 2.7 2.4 600 700 850 1100 1300 1500 1800 2000 2400 3200 3900 4500 5 9 5 9 9 19 19 36 36 120 120 120 35 35 50 50 60 50 60 50 60 40 50 60 4.9 3.8 6.4 4.8 5.5 3.5 3.9 2.6 3.0 1.5 1.7 2.0 4.5 4.0 4.0 3.7 3.4 3.4 3.3 3.2 3.1 2.9 2.7 2.4 600 700 850 1100 1300 1500 1800 2000 2400 3200 3900 4500 Undc 800V 54 66 49 59 58 73 70 86 80 112 111 109 Undc 1000V 49 60 45 54 53 66 64 79 75 107 103 102 Undc 1150V 46 56 42 51 50 64 61 75 72 99 99 99 Undc 1400V **Insert - - for male terminals or JE for female terminals 34 ■ JUNE 2015 43 51 40 47 46 58 56 69 66 96 93 91 Medium Power Film Capacitors FFLI 800V to 1400Vdc (RoHS Compliant) SPECIFICATION DC FILTERING CALCULATION FORM Your choice Capacitance C (μF) PN Working voltage Uw (V) Capacitance C (μF) Rms current Irms (Arms) Rated voltage Frequency f (Hz) Un (V) Ripple voltage Ur (V) Serial resistance Rs (mΩ) Ambient temperature θamb (°C) Rth (°C/W) Lifetime @ Uw,Irms and θamb hours Thermal resistance between hot spot and case Parasitic inductance L (nH) Cooling conditions CALCULATIONS Maximum ripple voltage Urmax = 0.2 Un Urmax = V The maximum ripple voltage of the selected capacitor must be in any case higher than the ripple voltage of your application Ratio Uw/Un ρ = Uw/Un ρ= Joule losses Pj = RsxIrms2 Dielectric losses Pd = Qxtgδ0=Qx 2.10 Hot spot temperature θHS = θamb+(Pj+Pd)xRth -4 Pj = W Pd = W θHS = °C The hot spot temperature must be in any case lower than 85°C LIFETIME EXPECTANCY VS HOT SPOT TEMPERATURE AND VOLTAGE 1.5 1.4 1.3 Uw/Un 1.2 1.1 1 θHS = 55ºC θHS = 65ºC θHS = 75ºC θHS = 85ºC θHS = 95ºC 0.9 0.8 0.7 100 1,000 10,000 100,000 1,000,000 Lifetime Expectancy (hours) Expected lifetime at hot spot calculated and U = Uw Dimensions millimeters (inches) JUNE 2015 ■ 35