Medium Power Film Capacitors FFLC DC FILTERING The FFLC series is specifically designed for DC filtering applications such as DC link or resonant filters. Large case sizes up to 35 liters and high specific energy up to 240J/l together with safe and reliable Controlled Self Healing Technology make this series particularly suitable for power converters in traction, drives and renewable energy areas. FFLC uses polypropylene metallized segmented film and it is fully dry technology. 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, feel free to contact your local AVX representative. PACKAGING MATERIAL Non-painted rectangular resin filled aluminium case Mounting brackets 4 M8/15 Female connections or M12/30 Male connections STANDARDS IEC 61071: Power electronic capacitors IEC 61881: Railway applications, rolling stock equipment, capacitors for power electronics IEC 60068-2: Environmental testing UL 94: Fire requirements NF F 16-101: Rolling stock – Fire behaviour – Materials choosing NF F 16-102: Rolling stock – Fire behaviour – Materials choosing, application for electric equipments EN 45545-2: Railways applications – Fire protection on railway vehicles Part 2 : Requirements for fire behaviour of materials and components HOW TO ORDER FFLC 3 1 M A 4427 Series Width 1 = 100mm 2 = 125mm 3 = 150mm 4 = 175mm Height 1 = 245mm 2 = 315mm 3 = 385mm 4 = 455mm 5 = 525mm 6 = 595mm Terminals F = Female M = Male Voltage A = 800V B = 900V C = 1000V D = 1100V E = 1350V Capacitance EIA code CHARACTERISTICS DEFINITIONS nominal value of the capacitance measured at θamb = 25 ± 10°C maximum operating peak voltage of either polarity (non-reversing rated DC voltage type waveform), for which the capacitor has been designed for Un continuous operation value of the maximum operating recurrent voltage for a given hot working voltage Uw spot temperature and an expected lifetime Ur ripple voltage peak-to-peak alternating component of the unidirectional voltage Ls parasitic inductance capacitor series self-inductance Rs capacitor series resistance capacitor series resistance due to galvanic circuit RMS current value for continuous operation under natural Irms thermal 1 convection generating 20°C overheating rms current value for continuous operation under forced air Irms thermal 2 generating 20°C overheating temperature of the cooling air measured at the hottest position of the capacitor, under steady-state conditions, midway between θamb (°C) cooling air temperature two units Cn θHS (°C) capacitance hot spot temperature 42 ■ JUNE 2015 Capacitance range Cn Tolerance on Cn Rated DC voltage Un Lifetime at Un and 70°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 Climatic Category 1750μF to 20600μF ±10% 800 to 1350V 100,000h 32 to 55nH up to 400Arms 1.5 x Un for 10s 4kVrms @ 50Hz for 10s polypropylene 40 / 85 / 56 (IEC 60068) -40°C / +85°C 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 Working temperature (according to the power dissipated) highest temperature obtained inside the case of the capacitor in thermal equilibrium Storage temperature Calorific value -40°C / +85°C 27 MJ/kg Medium Power Film Capacitors FFLC DC FILTERING LIFETIME EXPECTANCY VS HOT SPOT TEMPERATURE AND VOLTAGE 1.4 1.3 θHS = 55ºC Uw/Un 1.2 1.1 θHS = 70ºC 1.0 θHS = 85ºC 0.9 0.8 100 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 70°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 Rth1 and Rth2 (depending on cooling conditions) 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 Rth1 HS Rth2 CASE AMB -4 • tgδ0 = 2 x 10 (dielectric losses of polypropylene) Hot spot temperature will be: HS = amb + (Pj + Pd) x (Rth1 + Rth2) HS absolute maximum is 85°C If temperature is higher than 85°C, come back to #1 and start again with another selection. Rth1: thermal resistance between hot spot and case Rth2: thermal resistance between case and ambient air width JUNE 2015 ■ 43 Medium Power Film Capacitors FFLC 3. Refer to the curve and deduce the lifetime vs Uw/Un ratio 1.3 eg: rated voltage 1000V working voltage 950V ρ = 0.95 ⇒ lifetime 200,000 hours @ 70°C hot spot temperature Please, find a calculation form at the end of the catalog 1.2 Uw/Un DC FILTERING 1.4 .1.1 HS =70°C 1 0.95 0.9 0.8 100 1,000 10,000 100,000 200,000 1,000,000 Lifetime Expectancy (hours) THERMAL RESISTANCES Rth1 (°C/W): Thermal resistance between hot spot and case Height (mm) 245 315 385 455 525 595 100 0.56 0.41 0.3 0.25 0.2 0.17 Rth1 (°C/W) Width (mm) 125 150 0.67 0.76 0.49 0.56 0.36 0.41 0.3 0.34 0.24 0.27 0.21 0.24 Rth2 (°C/W): Thermal resistance between case and ambient air under natural convection and forced air Rth2 (°C) 175 0.82 0.6 0.44 0.37 0.3 0.26 Height (mm) 245 315 385 455 525 595 100 0.47 0.36 0.30 0.25 0.22 0.19 Natural air cooling Width (mm) 125 150 0.44 0.42 0.35 0.33 0.28 0.27 0.24 0.23 0.21 0.20 0.18 0.17 175 0.40 0.31 0.25 0.22 0.19 0.16 Forced air cooling >2m/s Width (mm) 100 125 150 175 0.23 0.22 0.21 0.20 0.18 0.17 0.16 0.16 0.15 0.14 0.13 0.13 0.13 0.12 0.11 0.11 0.11 0.10 0.10 0.09 0.10 0.09 0.09 0.08 For confined area, capacitor working in a closed cabinet, a thermal test under real conditions is necessary to evaluate the thermal resistance. PARASITIC INDUCTANCE VS SIZE Measurement @ 1MHz Height (mm) 245 315 385 455 525 595 100 32 34 36 38 40 42 Ls (nH) Width (mm) 125 150 34 35 36 38 39 41 41 44 43 47 46 51 44 ■ JUNE 2015 175 37 40 44 48 51 55 Low inductance design available on request Medium Power Film Capacitors FFLC DC FILTERING MTBF CALCULATION 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. JUNE 2015 ■ 45 Medium Power Film Capacitors FFLC DC FILTERING DIMENSIONS Female terminals Male terminals Max torque 15Nm Max torque 25Nm Available standard dimensions (other dimensions on request for specific design) H (mm): 245, 315, 385, 455, 525 and 595 W (mm): 100, 125, 150 and 175 WEIGHT VS SIZE mm Height 245 315 385 455 525 595 100 12 15 18.5 21.5 25 28.5 Weight (kg) Width 125 150 15 17.5 18.5 22.5 23 27.5 27 32.5 31.5 37.5 35 41.5 46 ■ JUNE 2015 175 20.5 26 32 37.5 42.5 48.5 Medium Power Film Capacitors TABLE OF VALUES Part Number Capacitance (μF) Width (mm) FFLC11 * MA4777 FFLC12 * MA6087 FFLC21 * MA6557 FFLC13 * MA7817 FFLC31 * MA8317 FFLC22 * MA8337 FFLC14 * MA9117 FFLC41 * MA1008 FFLC32 * MA1068 FFLC23 * MA1078 FFLC15 * MA1098 FFLC16 * MA1228 FFLC24 * MA1258 FFLC42 * MA1278 FFLC33 * MA1368 FFLC25 * MA1498 FFLC34 * MA1598 FFLC43 * MA1648 FFLC26 * MA1678 FFLC35 * MA1898 FFLC44 * MA1918 FFLC36 * MA2118 FFLC45 * MA2288 FFLC46 * MA2558 4,770 6,080 6,550 7,810 8,310 8,330 9,110 10,000 10,600 10,700 10,900 12,200 12,500 12,700 13,600 14,900 15,900 16,400 16,700 18,900 19,100 21,100 22,800 25,500 100 100 125 100 150 125 100 175 150 125 100 100 125 175 150 125 150 175 125 150 175 150 175 175 FFLC11 * MB3847 FFLC12 * MB4897 FFLC21 * MB5277 FFLC13 * MB6287 FFLC31 * MB6707 FFLC22 * MB6717 FFLC14 * MB7337 FFLC41 * MB8077 FFLC32 * MB8537 FFLC23 * MB8627 FFLC15 * MB8737 FFLC16 * MB9777 FFLC24 * MB1018 FFLC42 * MB1038 FFLC33 * MB1108 FFLC25 * MB1258 FFLC34 * MB1288 FFLC43 * MB1328 FFLC26 * MB1348 FFLC35 * MB1528 FFLC44 * MB1548 FFLC36 * MB1718 FFLC45 * MB1848 FFLC46 * MB2068 3,840 4,890 5,270 6,280 6,700 6,710 7,330 8,070 8,530 8,620 8,730 9,770 10,100 10,300 11,000 12,500 12,800 13,200 13,400 15,200 15,400 17,100 18,400 20,600 100 100 125 100 150 125 100 175 150 125 100 100 125 175 150 125 150 175 125 150 175 150 175 175 Height (mm) Rs (mΩ) Irms Thermal 1 (A) Irms Thermal 2 (A) 0.27 0.23 0.29 0.20 0.32 0.25 0.19 0.35 0.27 0.22 0.17 0.17 0.20 0.29 0.23 0.18 0.21 0.25 0.22 0.20 0.23 0.19 0.21 0.20 270 333 249 400 231 310 400 218 288 380 400 400 400 274 355 400 400 338 400 400 385 400 400 400 306 380 276 400 255 348 400 240 320 400 400 400 400 299 395 400 400 374 400 400 400 400 400 400 0.29 0.25 0.31 0.21 0.34 0.27 0.20 0.37 0.29 0.23 0.18 0.17 0.21 0.32 0.25 0.19 0.23 0.27 0.18 0.21 0.24 0.20 0.22 0.21 261 323 240 3100 222 300 400 209 278 369 400 400 400 264 344 400 393 327 400 400 373 400 400 400 296 368 267 400 245 337 400 231 309 400 400 400 400 289 383 400 400 362 400 400 400 400 400 400 Un = 800Vdc 245 315 245 385 245 315 455 245 315 385 525 595 455 315 385 525 455 385 595 525 455 595 525 595 Un = 900Vdc 245 315 245 385 245 315 455 245 315 385 525 595 455 315 385 525 455 385 595 525 455 595 525 595 * Insert F for female terminals or M for male terminals JUNE 2015 ■ 47 DC FILTERING FFLC Medium Power Film Capacitors FFLC DC FILTERING TABLE OF VALUES Part Number Capacitance (μF) Width (mm) FFLC11 * MC3167 FFLC12 * MC4027 FFLC21 * MC4337 FFLC13 * MC5177 FFLC31 * MC5517 FFLC22 * MC5527 FFLC14 * MC6037 FFLC41 * MC6647 FFLC32 * MC7017 FFLC23 * MC7097 FFLC15 * MC7187 FFLC16 * MC8047 FFLC24 * MC8277 FFLC42 * MC8467 FFLC33 * MC9027 FFLC25 * MC9857 FFLC34 * MC1058 FFLC43 * MC1098 FFLC26 * MC1108 FFLC35 * MC1258 FFLC44 * MC1278 FFLC36 * MC1408 FFLC45 * MC1518 FFLC46 * MC1698 3,160 4,020 4,330 5,170 5,510 5,520 6,030 6,640 7,010 7,090 7,180 8,040 8,270 8,460 9,020 9,850 10,500 10,900 11,000 12,500 12,700 14,000 15,100 16,900 100 100 125 100 150 125 100 175 150 125 100 100 125 175 150 125 150 175 125 150 175 150 175 175 FFLC11 * MD2537 FFLC12 * MD3227 FFLC21 * MD3487 FFLC13 * MD4147 FFLC31 * MD4427 FFLC22 * MD4437 FFLC14 * MD4837 FFLC41 * MD5347 FFLC32 * MD5637 FFLC23 * MD5697 FFLC15 * MD5757 FFLC16 * MD6447 FFLC24 * MD6647 FFLC42 * MD6797 FFLC33 * MD7247 FFLC25 * MD7907 FFLC34 * MD8447 FFLC43 * MD8737 FFLC26 * MD8857 FFLC35 * MD1018 FFLC44 * MD1028 FFLC36 * MD1138 FFLC45 * MD1218 FFLC46 * MD1368 2,530 3,220 3,480 4,140 4,420 4,430 4,830 5,340 5,630 5,690 5,750 6,440 6,640 6,790 7,240 7,900 8,440 8,730 8,850 10,100 10,200 11,300 12,100 13,600 100 100 125 100 150 125 100 175 150 125 100 100 125 175 150 125 150 175 125 150 175 150 175 175 Height (mm) Rs (mΩ) Irms Thermal 1 (A) Irms Thermal 2 (A) 0.30 0.26 0.33 0.23 0.37 0.28 0.21 0.40 0.31 0.24 0.19 0.18 0.22 0.34 0.26 0.20 0.24 0.29 0.19 0.22 0.26 0.21 0.23 0.22 253 314 232 385 215 291 400 202 269 358 400 400 400 255 334 400 382 317 400 400 362 400 400 400 287 358 258 400 237 326 400 223 299 400 400 400 400 279 372 400 400 351 400 400 400 400 400 400 0.33 0.28 0.36 0.24 0.40 0.31 0.22 0.44 0.34 0.26 0.20 0.19 0.24 0.37 0.28 0.22 0.26 0.31 0.20 0.23 0.28 0.22 0.25 0.23 243 303 223 373 206 280 400 194 259 346 400 400 395 245 323 400 370 306 400 400 350 400 400 400 276 345 248 400 227 314 400 214 288 392 400 400 400 269 359 400 400 339 400 400 388 400 400 400 Un = 1000Vdc 245 315 245 385 245 315 455 245 315 385 525 595 455 315 385 525 455 385 595 525 455 595 525 595 Un = 1100Vdc * Insert F for female terminals or M for male terminals 48 ■ JUNE 2015 245 315 245 385 245 315 455 245 315 385 525 595 455 315 385 525 455 385 595 525 455 595 525 595 Medium Power Film Capacitors TABLE OF VALUES Part Number Capacitance (μF) Width (mm) FFLC11 * ME1757 FFLC12 * ME2237 FFLC21 * ME2407 FFLC13 * ME2867 FFLC31 * ME3057 FFLC22 * ME3067 FFLC14 * ME3347 FFLC41 * ME3677 FFLC32 * ME3887 FFLC23 * ME3927 FFLC15 * ME3987 FFLC16 * ME4457 FFLC24 * ME4587 FFLC42 * ME4687 FFLC33 * ME4997 FFLC25 * ME5457 FFLC34 * ME5827 FFLC43 * ME6017 FFLC26 * ME6107 FFLC35 * ME6937 FFLC44 * ME7017 FFLC36 * ME7767 FFLC45 * ME8357 FFLC46 * ME9357 1,750 2,230 2,400 2,860 3,050 3,060 3,340 3,670 3,880 3,920 3,980 4,450 4,580 4,680 4,990 5,450 5,820 6,010 6,100 6,930 7,010 7,760 8,350 9,350 100 100 125 100 150 125 100 175 150 125 100 100 125 175 150 125 150 175 125 150 175 150 175 175 Height (mm) Rs (mΩ) Irms Thermal 1 (A) Irms Thermal 2 (A) 0.37 0.32 0.41 0.27 0.46 0.35 0.24 0.51 0.38 0.28 0.22 0.21 0.26 0.42 0.32 0.24 0.29 0.35 0.22 0.26 0.31 0.24 0.28 0.26 228 285 208 353 192 263 400 180 242 334 400 400 374 229 303 400 349 287 400 400 329 400 383 400 259 325 232 400 212 2100 400 199 270 378 400 400 400 251 337 400 393 318 400 400 365 400 400 400 Un = 1350Vdc 245 315 245 385 245 315 455 245 315 385 525 595 455 315 385 525 455 385 595 525 455 595 525 595 * Insert F for female terminals or M for male terminals JUNE 2015 ■ 49 DC FILTERING FFLC Medium Power Film Capacitors FFLC SPECIFICATION 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) Rth1 (°C/W) Lifetime @ Uw,Irms and θamb hours Thermal resistance between hot spot and case Parasitic inductance L (nH) Thermal resistance between case and ambient air Rth2 (°C/W) 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 Vw/Vn ρ = Uw/Un Joule losses Pj = RsxIrms2 Dielectric losses Pd = Qxtgδ0=Qx 2.10 Hot spot temperature θHS = θamb+(Pj+Pd)x(Rth1+Rth2) ρ= -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 1.4 1.3 θHS = 55ºC 1.2 Uw/Un DC FILTERING CALCULATION FORM 1.1 θHS = 70ºC 1.0 θHS = 85ºC 0.9 0.8 100 1,000 10,000 Lifetime Expectancy (hours) Expected lifetime at hot spot calculated and U = Uw 50 ■ JUNE 2015 100,000 1,000,000