FIM Products FIM Technology TPC (acquired by AVX Corporation in 1998) is at the forefront of high performance film capacitor technology improvements for 30 years. In 1979, we developed CONTROLLED SELF-HEALING technology specifically to enhance the performance of film power capacitors. This enables the capacitor to continue to function without catastrophic failure by insulating the weak points of the dielectric material. During operation, the capacitor behaves like a battery. It will consume capacitance via the gradual breakdown of individual cells until it decreases down to 2% of the original value. Since 1988, FIM technology launching year, we continuously improve performances to meet DC filtering power applications. FIM technology with polypropylene Film, vegetable oil Impregnated and aluminium Metallization combines totally safe behavior and high energy density. FIM technology is available in CAPAFIM, TRAFIM and FILFIM ranges for DC filtering applications. Also available in DISFIM range for energy storage and discharge applications. 2 FIM Products Characteristics ELECTRICAL CHARACTERISTICS FOR DC FILTERING Cn Capacitance Vn Rated DC voltage Vw Working voltage Vr Ripple voltage VI Insulation voltage Ls Stray inductance Rs Capacitor series resistance tan δ Tangent of loss angle Irms Working current Imax Maximum current 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. Rms rated value of the insulation voltage of capacitive elements and terminals to case. Capacitor series self-inductance. Capacitor series resistance due to galvanic circuit. Ratio between the equivalent series resistance and the capacitive reactance of a capacitor at a specified sinusoidal alternating voltage, frequency and temperature. Rms current value for continuous operation. Maximum Rms current value for continuous operation. THERMAL CHARACTERISTICS θamb (°C) Cooling air temperature Temperature of the cooling air measured at the hottest position of the capacitor, under steady-state conditions, midway between two units. 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. θHS (°C) Hot spot temperature Highest temperature obtained inside the case of the capacitor in thermal equilibrium. θ (°C) Operating temperature Temperature of the hottest point on the case of the capacitor in thermal equilibrium. θmin (°C) Minimum operating temperature Lowest temperature of the dielectric at which the capacitor may be energized. θmax (°C) Maximum operating temperature Highest temperature of the case at which the capacitor may be operated. 3 FIM Products General Description Three series, for DC filtering applications, are proposed with nominal voltage from 1200V up to 56kV. CAPAFIM DC filtering application up to 3.9kV Capacitance up to 1620µF TRAFIM DC filtering application up to 6kV Capacitance up to 16100µF • Standard shape base 340x165 • Book shape base 340x117 which allows: Lower thermal resistance Higher Rms current capability Lower serial resistance Higher thermal exchange Lower stray inductance FILFIM High voltage DC filtering available up to 100kV on specific design Capacitance up to 612µF For any specific request about capacitance value, voltage, size or shape, contact your AVX local representative request by using the form on page 30. STANDARDS IEC61071 Capacitors for power electronics IEC61881 Capacitors for power electronics, railway applications, rolling stock equipment IEC61373 Railway applications, rolling stock equipment, shock and vibration tests IEC60068 Environmental testing NFF16-101 Railway rolling stock, fire behavior NFF16-102 Railway rolling stock, fire behavior 4 FIM Products General Description LIFETIME EXPECTANCY VS HOT SPOT TEMPERATURE AND VOLTAGE 1.7 1.6 1.5 HS = 50°C Vw/Vn 1.4 1.3 HS = 70°C 1.2 1.1 HS = 85°C 1 HS = 80°C 0.9 0.8 100 1000 10000 100000 1000000 Lifetime Expectancy (hours) TANGENT OF LOSS ANGLE VS FREQUENCY 60 50 tgδ (10e-4) 40 Typical Curve @ 1V/25ºC 30 20 10 0 10 100 1000 f(Hz) 5 FIM Products General Description TANGENT OF LOSS ANGLE VS TEMPERATURE 30 25 tgδ (10e-4) 20 Typical Curve @ 50Hz on Schering Bridge 15 10 5 0 0 10 20 30 40 50 60 70 80 (ºC) ΔC/C VS HOT SPOT TEMPERATURE ΔC/C(%) 4 3 Typical Curve @ 1V/100Hz 2 1 (ºC) 0 -55 -35 -15 5 -1 -2 -3 -4 6 25 45 65 85 FIM Products General Description DIMENSIONS MARKING Dimensions are indicated in the value tables as well as the weight. Dimensional tolerances are: H ± 3mm, W ± 3mm Initially, the large faces of the capacitor may be slightly convex. At delivery the maximum width is: W’max = W +15mm Standard material is stainless steel. Aluminum is available for specific requirement to reduce the weight or induction effect. The label is usually located 50mm from the top of the case and centered to the length: TPC or AVX Logo Test voltage between terminals and case Part number Capacitance and tolerance Batch and serial number Rated voltage in clear Date of manufacture MOUNTING Vertical mounting is the preferred and horizontal is acceptable. Please contact AVX for up-side down mounting configuration. HANDLING When unpacking, it is important that no mechanical shocks occur that might deform the cans and damage the output connection. The capacitors include, unless otherwise specified, one or several gripping elements (mass screws, jack rings or other hoisting devices); they should be exclusively handled by means of these elements. In no case should the electrical output terminals be used to lift the capacitor. The grounding wire should be kept in place until the capacitor is mounted. ASSEMBLY AND INSTALLATION To check for the absence of excessive mechanical stresses. The mechanical stresses in assembly should remain compatible with the characteristics of the capacitor. The method of mounting should not lead to the deformation of the capacitor case. Tightening torques are given below: Output through threaded connections: max = 25 N-m Mechanical mounting Moreover vertical position is the preferential one and horizontal is accepted. In order to enable air convection, it is necessary to maintain at least 40mm between the large faces of adjacent capacitors. Connections They should not induce any force on the output terminals. Flexible connections should be used (braided or thin metal). The cross section should not be less than: S = 0.2 x Imax where S (mm2) and Imax (A) The skin effect, which occurs vs frequency, must also be taken into account. SAFETY The FIM technology provides excellent safety; there is no risk of explosion in case of defect throughout the life of the capacitor. This explains why there is no need to equip these capacitors with pressure switch. Rapeseed oil is not explosive or flammable at normal conditions, therefore capacitors can be transported without being subjected to safety rules. Rapeseed oil flash point is about 317°C and the polypropylene flash point is near 300°C, so the melting certifies a temperature of security above 300°C. In case of fire above this temperature, it is recommended to use dust or CO2. The use of water is contra-indicated. The possible rejected products during fire are CO2, H2O, CO (in case of non-complete combustion), Hydrocarbons and some other gases. Carrying mask is required for protection. OIL The only impregnant used in TRAFIM capacitors is rapeseed oil (otherwise known as Canola oil) and then is fully environmentally compatible. It does not emit toxic or carcinogenic gases, nor is it harmful to soil, water or humans in the event of accidental spillages. As a natural product derived from foodstuff, it is even edible. Of all the vegetable oils, rapeseed oil has one of the best thermal stabilities and lowest acidity levels. NON-TOXIC COMPOSITION Our capacitors are free of: Arsenic, Asbestos, Beryllium, Brominated flame retardants (PBB and PBDE), Cadmium, CFC, HCFC, Cobalt, Formaldehyde, Halon, Isocyanatos, Mercury, Nickel PCB, PCT, Polyaromatic Hydrocarbons (PAH), Phtalates, PVC, PTFE and Thirams. Lead is only found in soldering (for approximately 0.3% of the capacitor weight). Free of SF6. CALORIFIC VALUE A formula that gives the calorific value of a standard TRAFIM capacitor is: CV (MJ) = L x [4 x 10-5 x W x H - 1.3 x 10-5 x H + 8 x 10-4 x W + 4.55 x 10-2] + 3.75 x N where H, L, W, are Height, Length and Width in millimeters, and N is the number of terminals. DESTROYING CAPACITORS The destruction of the capacitors are subject to the laws in force in each country. In practice, today, please contact AVX for a list of companies who can take charge of the products to be destroyed. 7 FIM Products General Description CAPACITOR DESIGN The capacitor lifetime depends on the working voltage and the hot spot temperature. Our caps are designed for 100000 hours lifetime at nominal voltage and 70°C hot spot temperature. According to your operating conditions, you will need to calculate the hot spot temperature, and deduce from this calculation if the lifetime obtained can suit your application. 1 According to the tables, you should find a capacitor with required capacitance Cn and voltage Vn with Vn>Vw. 2100 Copy out: Serial resistance (Rs): see table of values Thermal resistances Rth1 and Rth2 (depending on cooling conditions): See page 13 for CAPAFIM page 16 for TRAFIM page 24 for FILFIM Voltage Calculate the maximum ripple voltage allowed for the chosen cap and check if Vr<0.45Vn. 2000 Vn 1900 Vw 1800 Vr 1700 1600 Vw = working voltage Vn = nominal voltage Vr = ripple voltage 1/f 1500 Time 2 Hot spot temperature calculation Total losses are calculated as follow: Pt = Pj + Pd Rth1: Thermal resistance between hot spot and case Rth2: Thermal resistance between case and ambient air Joule losses: Pj = Rs x Irms2 Dielectric losses: Pd = Q x tgδ0 with - Q = reactive power; Irms2 / (C x 2 x x f) for a sinusoidal waveform - tgδ0 = dielectric losses of polypropylene + rapeseed oil (tgδ0 = 3 x 10-4) Hot spot temperature will be: θHS = θamb + (Pj + Pd) x (Rth1 + Rth2) θHS absolute maximum is 85°C If temperature is higher than 85°C, choose a bigger cap. 8 Rth1 HS Rth2 case amb FIM Products General Description 3 Refer to curve and deduce the lifetime vs Vw/Vn ratio. LIFETIME EXPECTANCY VS HOT SPOT TEMPERATURE AND VOLTAGE 1.3 1.25 1.2 1.15 HS = 70°C Vw/Vn 1.1 1.05 1 0.95 0.9 0.85 0.8 10000 100000 200000 1000000 Lifetime Expectancy (hours) Ex: nominal voltage 2000V working voltage 1900V ρ = 0.95 ⇒ lifetime 200000 hours @ 70°C hot spot temperature You can find a calculation form on page 28 at the end of the catalog. For any help or specific requirements, please contact your AVX local representative. 9 FIM Products General Description MTBF CALCULATION Based on 20 years of test results, we have established the following relation. The failure rate λΒ depends on the hot spot temperature θHS and the charge ratio ρ: ρ = Vw/Vn 5.861 (ρ - 1) λΒ = 3x10 ×e [3.98 ⎧⎩ 30.35 (θ _________ HS +273)⎫ ⎭ 358 ] × 10 -9 in failures/hour GENERAL FAILURE RATE λ = λΒ × πQ × πΒ × πE failures/hour πQ, πΒ and πE see following tables Qualification Qualification factor πQ Product qualified on IEC 61071 and internal qualification 1 Product qualified on IEC 61071 2 Product answering on another norm 5 Product without qualification 15 Environment On ground (good conditions) Environment factor πE 1 On ground (fixed materials) 2 On ground (on board) 4 On ship 9 On plane 15 Environment Environment factor πΒ Favorable 1 Unfavorable 5 MEAN TIME BETWEEN FAILURE (MTBF) M.T.B.F. = 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). 10