webinar 85 85-box_dc_link

September 4th, 2017

KEMET Webinar - 85/85, Box DC link Standard & Auto

Products

EMI Film Capacitors

✓ Box - Polypropylene F862, F863

DC Link

✓ Box – Polypropylene C4AE

✓ Box - Polypropylene C4AQ (AEC Q200)

EMI Film Capacitors

Purpose of EMI capacitors: Noise Filtering

• To reduce/mitigate generated EMI energy inthe range of 150 kHz to 30 MHz

ofr m leaving the equipment and then interfering with other devices connected to the Mains

EN/IEC 60384-14 (2013)IEC 60384-14

UL 60384-14

CAN/CSA E60384-14

CQC IEC 60384-14

0.15 30.000.50 1.00 5.00 10.000

100

10

20

30

40

50

60

70

80

90

周波数

レベル

[MHz]

[dB(μV)]

R

4

6

,

R

4

1

Noise

generated by

the device

Noise level to be

granted by

capacitorsCISPR11 QP LimitCISPR11 AV Limit

Frequency

• EMI Film Capacitors are directly connected to

the mains: safety in performance is a must.

Failure mode must be open circuit

• cUL, ENEC, CQC are the international

standards applied to EMI Capacitors

• Standard X2

• Special X2 for harsh environmental

conditions F862, F863

Purpose of EMI Capacitors:

Capacitive Power Supply

• Capacitance stability is a must to control

current flowing to the load.

• EMI Film Capacitors are directly connected to

the mains: safety in performance is a must.

Failure mode must be open circuit

• cUL, ENEC, CQC are the international

standards applied to EMI Capacitors

F862, F863

EN/IEC 60384-14 (2013)IEC 60384-14

UL 60384-14

CAN/CSA E60384-14

CQC IEC 60384-14

EMI Film Capacitors Main Features

- High safety performances

- Good volumetric efficience

- Low/medium costs

- Small size

- High competition

- New generation with better resistance to humidity

Agencies Approvals

(cUL, ENEC, CQC)

In Parallel to the

Mains

In Series to the

Mains

In Series to the

Mains - In door

application

X2 Required – Cx

F862, F863 or

Standard X2 F862 F862,F863

Market Trend Demand New

The 85°C/85%.R.H. @ 240 Vac test on the component ensure that the capacitor has been designed to be

stable in Capacitance and Dissipation Factor even in outstanding applications

Customers more and more ask for EMI Film components having better performances than usual in terms of capacitance stability and also considering harsh environmental conditions.

EMI Filtering in Harsh Environmental conditions

Harsh Environmental Conditions

and Potential Effects

• Harsh environmental conditions

High Relative Humidity (R.H.) combined with temperature can deteriorate the internal film metalization

and then cause the following:

Capacitance drop

• the device will emit EMI and damage other devices (X2 in parallel)

• In series connection the device doesn’t work anymore

Dissipation Factor increase

• the capacitor will be overheating and damaging

the device (X2 in Parallel to the mains)

Humidity Impact to Capacitance Stability

4. Electrochemical Corrosion

Reactions in the electrochemical cell are driven by applied voltage

Corrosion rate is directly proportional to: Temperature, Humidity

and Bias

Phenomena is fixed selecting special materials and setting up a

special production process

Electrochemical cell

Applied AC voltage

Air gap induced voltageZn° → Zn2+ + 2 e-

2 H2O + 2 e- → H2 + 2 OH-

F862 – F863 EMI Capacitors Stability and Safety

Combination

Safety

Self-healing mechanism allows to withstand high voltage peaks without causing catastrophic phenomena.

The self-healing property allows a local evaporation of the metallized coating layer isolating the affected fault area and

restoring the insulation resistance between the electrodes. Capacitance drop is negligible.

Capacitor section and self healing mechanism

Stability

The metallized coating layer on the dielectric must be extremely thin to facilitate

the correct evaporation of the deposited metal.

Severe environmental conditions, high temperature and humidity, can determine

corrosion phenomena: dissipation factor increase and capacitance drop reducing

the reliability of the component.

New technologies that results in special materials and manufacturing processes

allows to make components stable in capacity and dissipation factor.

Metalized Film

Reasons to Choose Polypropylene Dielectric -Self Healing Performances for Safety

– In general alyphatic polymers as polypropylene (and paper) are

highly efficient at self-healing because the pyrolisis reaction during

clearing results in stable gaseous products which allow full recovery

of insulation resistance.

– X2 capacitor have to withstand to high voltage pulse and

good selfhealing property is required for safety reasons

PolyPropylene

CH4, CO2

Polypropylene and Polyester comparison

– Self-healing of Polyester type polymers is lower: the aromatic group in the polymer is very

stable and pyrolisis will result less effective. High magnitude clearings could result in ‘carbon’

byproducts (soot), which could be detrimental for insulation resistance.

– Among commonly used polyesters, PET is performing good: the fraction of aromatic groups in

the polymer chain is lower than e.g. PEN.

PET

PolyethyleneTerephthalatePEN

PolyethyleneNapthalate

Polypropylene Zn metalized has much better performances

than Polyester in case of peak voltage from the mains

Reasons to Choose Polypropylene Dielectric -Self Healing Performances for Safety

F862 – F863 How to Detect Stability

The Temperature-Humidity-Bias

(THB) test @ 85°C, 85% relative

humidity and 240 Vac of operating

voltage allows to detect

the significant improvement in the

capacity stability and dissipation

factor of the new components

compared to those

currently used in standard

applications

F862 85/85/1000 Hours

• Big size

F863 85/85/500 Hours

• Reduced size

Heavy Duty Series: F863

Suppressor Capacitors Applications and Benefits

INDUSTRIAL

The use of polypropylene dielectric not only provides excellent self-healing performance, but thanks to its low and stable dissipation factor, greatly

improves the ability to withstand the high frequency ripple currents coming back from the switching stage of the inverter.

F863• Small size

• Long life

• Capacitance and DF Stability

• THB test 85/85/500 Hours



AUTOMOTIVE Battery Chargers

The improved environmental performances and self-healing ability of these components also meet the requirements of the automotive industry when

used in the Plug-in Hybrid Electric Vehicles (PHEVs) and Electric Vehicles (Evs) Battery Chargers. For this reason these new components meet the

AEC-Q200 qualification requirements in addition to the international safety regulations according to ENEC, UL, cUL and CQC approvals.

F863• Small size

• Long life





In door application Capacitive Power Supply

F863• Small size

• Long life



Heavy Duty Series: F862 – F863


SMART METER

F862 is suitable for application in the capacitive Power Supply or in the coupling stage of data transmission

F863 can be applied in parallel tp the mains when SMPS needs EMI filter

F862• Larger size

• Very Long life

• Very high Capacitance and DF Stability


F863• Small size

• Long life



DC Link Film Capacitors

C4AE Boxed DC Link

Input Voltage Filtered Voltage

Rectifier IGBT

Output Voltage

Converted to

other frequency

C

DC-Link capacitors are important components in the majority of power electronic equipment to improve the

efficiency of the systems, balancing the power difference between the input source and output load, and

minimizing voltage variation.

Film capacitor advantages:

- Handle a reverse voltage

- Able to withstand fast charge/discharge conditions

- Designed for high rms currents

- High reliability due to self-healing properties

- Long life expectancy

- Storage without any problems

C4AE C4AQ Boxed DC Link AEC Q200

C4AEC4AQ

• Samples now

• Mass production Oct 2017

➢ Higher operating temperature 105°C;

➢ Higher Lifetime at 105°C;

➢ AEC – Q200 qualification;

➢ Operating range -55°/+105°C;

Rated voltage VR 450 – 1,100 VDC (@85°C)

Capacitance range 1.0 µF to 130.0 µF

Capacitance Tolerance ±5%, ±10%

Temperature Range ‐40°C to 85°C

Dissipation Factor PP typical (tgδ0) ≤ 0.0002 at 10 kHz and +25°C (±5°C)

Surge voltage 1.5 * VNDC for maximum 10 times in life time at 25°C

Overvoltage

(IEC 61071)

1.15 * VNDC for maximum 30 minutes - once per day

1.3 * VNDC for maximum 1 minute - once per day

Peak non Repetitive Current 1.5 * IPKR - maximum 1,000 times in life time

Insulation Resistance IR x C ≥ 30.000 seconds at 100 VDC 1 minute (+25°C)

Capacitance deviation in operation±2% maximum on capacitance value measured at

(+25°C)

Test Voltage between terminations 1.5 * UNDC for 10s or 1.65 * UNDC for 2s @ +25°C.

Permissible Relative Humidity -

Storage

Annual average ≤ 70%; 85% on 30 days/year randomly

distributed throughout the year. Dewing not admissible

Rated Voltage (VDC) @ 85°C 450 600 700 900 1100

Operative Voltage (VDC) @ 70°C 500 650 800 1100 1300


Rated voltage VR 500 – 1,300 VDC (@70°C)

Capacitance range 1.0 µF to 130.0 µF

Capacitance Tolerance ±5%, ±10%

Temperature Range ‐55°C to 105°C

Dissipation Factor PP typical (tgδ0) ≤ 0.0002 at 10 kHz and +25°C (±5°C)

Surge voltage 1.5 * VNDC for maximum 10 times in life time at 25°C

Overvoltage

(IEC 61071)

1.15 * VNDC for maximum 30 minutes - once per day

1.3 * VNDC for maximum 1 minute - once per day

Peak non Repetitive Current 1.5 * IPKR - maximum 1,000 times in life time

Insulation Resistance IR x C ≥ 30.000 seconds at 100 VDC 1 minute (+25°C)

Capacitance deviation in operation±2% maximum on capacitance value measured at

(+25°C)

Test Voltage between terminations 1.5 * UNDC for 10s or 1.65 * UNDC for 2s @ +25°C.

Permissible Relative Humidity -

Storage

Annual average ≤ 70%; 85% on 30 days/year randomly

distributed throughout the year. Dewing not admissible

Rated Voltage (VDC) @ 70°C 500 650 800 1100 1300



DC Link Film Capacitors Applications – Industrial C4AE

• Regenerative drives

• Motor drives

• Inverters

• Welding machines

• Rectifiers

• SMPS

• Solar converters

• Ventilation systems

Electrical Vehicle DC Onboard EMI Filter

ACprotection

DC Filter

C4AQ C4AQ

R41 R41 R41 R41

On board

Electric Vehicle Charging Stations/On Board Battery

Chargers

C1

C2

C2

C3 C4 C5

C6

85V~265Va

c C6 –Output

FilteringC4AQF863

R41

R41

R75R74

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