ABB 5SHY6545L0001 AC10272001R0101 5SXE10-0181 High-Power IGCT Module

ABB 5SHY6545L0001 AC10272001R0101 5SXE10-0181 High-Power IGCT Module

Product core positioning

The ABB 5SHY6545L0001 AC10272001R0101 5SXE10-0181 module is an integrated gate commutated thyristor (IGCT) module developed by ABB for the field of medium and high voltage high-power power electronics. "5SHY6545L0001", "AC10272001R0101", and "5SXE10-0181" are codes for different dimensions of the product (material code, series code, specification code), belonging to the ABB Power Semiconductors series high-power semiconductor product system. Its core function is to serve as the core switching device of the power conversion system, achieving precise commutation control under high voltage and high current. It combines the high voltage withstand capability of thyristors with the fast switching characteristics of transistors, and is widely used in high-power power electronic devices such as high-voltage inverters, flexible AC transmission systems (FACTS), and industrial energy storage converters. It provides efficient and reliable power conversion solutions for scenarios such as new energy grid connection, industrial motor speed regulation, and power grid upgrading and transformation.

Key technical parameters

1. Electrical performance parameters

Rated voltage and current: Rated blocking voltage (VDRM) 4500V, rated on state current (ITAV) 1200A (effective value), peak on state current (ITSM) 8000A (10ms), can meet the current and voltage requirements of medium and high voltage high-power systems.

Switching characteristics: turn-on time ≤ 3 μ s, turn off time ≤ 5 μ s, maximum commutation frequency up to 1kHz, achieving fast switching control and reducing switching losses while ensuring high-power transmission.

On state voltage drop: Under rated current, the on state voltage drop (VT) is ≤ 2.2V, designed with low conduction loss to improve the overall efficiency of the converter system and reduce energy waste.

2. Gate pole control parameters

Gate driving voltage: Turn on the gate voltage (VGE (on))+15V ± 1V, turn off the gate voltage (VGE (off)) -10V ± 1V, compatible with ABB's dedicated IGCT gate driving unit (such as 5SDF05H1200), ensuring stable transmission of gate control signals.

Gate current requirement: peak gate current (IG (on)) ≤ 80A when turned on, peak gate current (IG (off)) ≤ 60A when turned off, gate static current (IGQ) ≤ 10mA, low gate power consumption design, simplified drive circuit heat dissipation.

3. Heat dissipation and environmental parameters

Thermal resistance characteristics: The junction to shell thermal resistance (Rth (j-c)) is ≤ 0.008K/W, and it needs to be used with a dedicated water-cooled radiator (such as ABB 3ADT300091R1001) or air-cooled radiator to ensure stable heat dissipation of the module under high load.

Environmental adaptability: working temperature range (Tj) -40 ℃~125 ℃, storage temperature range -40 ℃~150 ℃, relative humidity 5%~95% (no condensation), can work stably in harsh power electronic operating environments such as high temperature and high humidity; The insulation level is Class II according to IEC 60664-1, with an insulation voltage (Vis) of 6000V AC (1min), ensuring the electrical safety of the module.

4. Physical and packaging parameters

Packaging form: Adopting ABB standard press pack packaging, the shell material is a ceramic and metal composite structure, with high mechanical strength and good insulation performance. The size is about 180mm × 120mm × 50mm, suitable for installation in standard power electronic cabinets.

Pin configuration: Includes 2 main electrodes (anode A, cathode K) and 1 gate electrode (G). The main electrode uses M12 threaded crimping terminals, and the gate electrode uses a dedicated quick connector for easy connection to external circuits, with low contact resistance and reduced current transmission losses.

Core functions and features

High power density and high efficiency: With high rated parameters of 4500V/1200A and low-pass voltage drop characteristics, a single module can achieve high-power power conversion without the need for multiple modules in parallel, simplifying the system topology structure; A high conversion frequency of 1kHz can reduce the size and weight of filtering components, improve the power density and energy conversion efficiency of the entire converter system. For example, in a 10kV high-voltage inverter, using this module can reduce the volume of the inverter by 20% and increase efficiency to over 98.5%.

Strong reliability and anti-interference ability: using crimping packaging technology, the internal chips of the module are in close contact with the electrodes, with strong seismic performance, and can adapt to the vibration environment of industrial sites; The gate drive circuit has overvoltage, overcurrent, and overheating protection functions. When the module experiences overvoltage (exceeding VDRM), overcurrent (exceeding ITSM), or high junction temperature (exceeding 125 ℃), the drive unit will immediately cut off the gate signal, force the module to shut down, and avoid module damage; At the same time, the module has good electromagnetic compatibility (EMC) and complies with the IEC 61800-3 standard, which can resist grid harmonics and external electromagnetic interference, ensuring stable operation in complex power environments.

Easy to maintain and compatible with the system: The crimping packaging design makes module installation and replacement convenient, without the need for welding, and can be connected to the heat sink and circuit through bolt crimping, reducing maintenance time and difficulty; The module is compatible with ABB's full range of high-power converter control systems (such as the ACS 6000 series high-voltage inverter control system), and can be seamlessly integrated with ABB gate drive units and protection units, reducing the difficulty of system integration and shortening the R&D and debugging cycle.

Environmental Protection and Long Life: Adopting lead-free soldering technology and environmentally friendly packaging materials, in compliance with RoHS environmental standards, reducing pollution to the environment; The mean time between failures (MTBF) of the module is ≥ 100000 hours, and its service life can reach more than 15 years, reducing equipment replacement frequency and maintenance costs. It is suitable for long-term continuous operation scenarios such as wind power generation and rail transit.

Typical application scenarios

1. Core application areas

New energy generation

Wind power inverter (1.5MW~6MW wind turbine), photovoltaic inverter (10kV centralized inverter)

As a core switching device, it realizes the AC/DC conversion of wind and solar energy and grid connection control, ensuring the smooth and efficient integration of new energy into the grid

Industrial transmission

10kV~35kV high-voltage frequency converter (used for speed regulation of mine main motors and steel rolling mill motors)

Realize variable frequency speed regulation of high-voltage and high-power motors, reduce motor starting current, improve motor operating efficiency, and save industrial electricity

Flexible AC transmission

Static Var Generator (SVG), Static Synchronous Compensator (STATCOM)

Quickly adjust the reactive power of the power grid, improve the power factor of the power grid, suppress voltage fluctuations and harmonics of the power grid, and enhance the stability and power supply quality of the power grid

Rail Transit

Metro and high-speed rail traction converter (25kV traction power supply system)

Realize the conversion of AC power in the traction network to DC power in the traction motor, control the speed of the traction motor, and ensure the smooth start, acceleration, and braking of the train

Industrial energy storage

Megawatt level energy storage converter (PCS) (for lithium battery energy storage power plants)

Realize bidirectional conversion between DC power from energy storage batteries and AC power from the power grid, complete the storage and release of electrical energy, and smooth out load fluctuations in the power grid

2. Example of System Integration

In the converter system of a 2.5MW permanent magnet direct drive wind turbine, the ABB 5SHY6545L0001 IGCT module serves as the core switching device and forms a complete converter scheme with the ABB 5SDF05H1200 gate drive unit and ACS 800 series control system. The AC power generated by the wind turbine is rectified into DC power by a rectifier, and the module serves as the core switching device of the inverter, which inverts the DC power into AC power of the same frequency and phase as the grid. At the same time, the gate drive unit and control system achieve precise control of the module switch state, adjust the output voltage and frequency, and ensure stable grid connection of wind level; When there is voltage drop or harmonic interference in the power grid, the module can respond quickly (response time ≤ 10 μ s), adjust the output power, and ensure the stable operation of the wind turbine and the power grid.