1. IGBT Modules for Wind & Solar Power Application - 2011

2. Wind Turbine Overview Off-shore c b On-shore a Blade Nacelle Hub
Generator
Gear (Optional)
Gear
3 Φ
a) Four-pole generator with Gear
Yaw control
Brake b
b) Multi-pole generator without Gear
On-shore
Tower
3 Φ
Cable
c) Schematic drawing
Wind Converter a
Grid
MV Transformer
2018/11/6

3. Double Feed Induction Generator (DFIG)
Typical converter power:
1.25MW, 1.5MW, 2MW (Typ.), 3MW
Typical topology:
B6I+B6I converter and inverter
Overvoltage protection crow-bar
Opt. brake chopper
Advantages:
Power converter only for 30% generated power
Line inductance is only 3%~4.5%.
Crowbar
Chop
Bipolar diodes and SCR
EconoPACK+,
EconoDUAL
PrimePACK
IHM (IHM B)
2018/11/6

4. Full Power Wind Generator (4Q)
Typical converter power:
1.5MW, 2MW (Typ.) up to 5 MW
Typical topology:
B6I + B6I converter and inverter
Brake chopper
Opt crow-bar
Advantages:
Simple AC induction generator
Generated power and voltage increase with the speed.
Crowbar
Chop
Bipolar diodes and SCR
EconoPACK+,
EconoDUAL
PrimePACK
IHM (IHM B)
2018/11/6

5. Full Power Wind Generator (2Q)
Typical converter power:
300 kW
Typical topology:
B6U or B6C rectifier,B6I inverter
Brake chopper
Opt. boost converter
Advantages:
Simple Generator Side Converter and Control
No min./max. Turbine Speed Limits
Chop
Bipolar diodes and SCR
EconoPACK+,
EconoDUAL
PrimePACK
IHM (IHM B)
2018/11/6

6. Summary of different wind turbine
Generator
type
Generator output voltage
Generator frequency (mechanical)
DC-link voltage
output voltage turbine before trans.
Switching frequency
Reverse Voltage IGBT
Asynchronous (danish concept)
3x690V
50 Hz
n.a.
Double feed Induction geneartor (DFIG)
variable
1100V
e.g. 2,25 kHz grid and rotor sided
1700V
Synchronous
3x500V 3x690V 3x960V
650V 1100V 1800V
3-4kHz 3-4kHz 0,5-1kHz
1200V 1700V 3,3kV
2018/11/6

7. DFIG - Working state & power flow
Electromagnetic power PM
Mechanical power
Pm=(1-s)*PM
Slip power
s*PM
Under the rated working point, the output power is in
proportion with rotation speed.
Above rated working point, the system will change the
angle of blade to reduce the output power rate.
2018/11/6

8. Rotor side inverter feature
Rotor side voltage is in proportion with s, when rotor speed is higher than synchronize speed (s<0); and in inverse proportion with s, when speed lower than synchronize speed (0<s<1)
Output current is nearly same, when s<0.
The overload coefficient of rotor side inverter is small.
1>S>0
S<0
2018/11/6

9. Requirements on IGBT modules -> Reliability
Lifetime and reliability: normally 20 years, zero failure
Requirement to IGBT modules:
Load cycle capability (power and thermal cycling capability)
Different temperature swings depending on different converter topologies
Alternate current frequency of LSC: 50Hz or 60Hz.
Alternate current frequency of MSC: 0..20Hz.
Assuming the same power dissipation:
Temperature swing in the MSC (IGBTs+diodes) is much higher.
As frequencies smaller 5Hz, the chip temperature follows the current fairly exactly.
LSC
MSC
typical DFIG system
2018/11/6

10. Requirements on IGBT modules -> PC capability
The different temperature swings of a typical DFIG in the semiconductors are shown.
ΔTj
LSC (fundamental oscillation 50Hz):
Temperature swing in the IGBT
Temperature swing in the diode
MSC (fundamental oscillation 1Hz):
Temperature swing in the IGBT
Temperature swing in the diode
Machine side converter (MSC) needs to be specifically designed/oversized to meet the required power cycling and thermal cycling capability for a defined life time 20 years.
2018/11/6

11. Requirements on IGBT modules -> LVRT
Why LVRT required?
The wind converter stay connected to the network and keep the operation following the voltage dip caused by short-circuit on any or all phases.
The wind power penetration is very high, the tripping of large wind farm will cause the load changing violently even power system blackout.
Grid fault keeps wind turbine continuous operation within specified time range.
2018/11/6

12. LVRT Challenges for DFIG System – Symmetrical Fault
Typical Converter Design for DFIG
Stator/rotor winding ratio 1:3
Stator 50Hz, rotor 0—17Hz
Stator voltage roughly the same as maximum rotor voltage
Converter power is only 1/3 of stator power
DC link voltage, and voltage rating of IGBT designed according to rotor voltage
DFIG - Grid Low Voltage Ride Through
Stator flux almost freeze during ZVRT, decaying in roughly
Induced rotor terminal exceed DC link voltage, up to 4 times
Current control of converter are actually converting mechanical energy into DC link, similar to a synchronous generator in principle
Equivalent circuit for DC flux
2018/11/6

13. Impact on Converter Design – Symmetrical Grid Fault
DFIG - Grid Low Voltage Ride Through
Rotor-side IGBT to conduct peak current about 4 times of the nominal
Quick control of line-side converter current after transient
transient air-gap torque around 4 times of the nominal, active damping required
rotor-side converter to conduct large DC current component
Challenge in DC voltage control
Quick control, transient large current capability, and DC protection is the key.
DFIG LVRT – Symmetrical Fault
2018/11/6

14. LVRT Challenges for DFIG System – Unbalanced fault
Equivalent circuit for negative sequence flux
DFIG - Grid Low Voltage Ride Through
Line-line short, grid voltage Vneg=Vpos=0.5Vnom
Negative sequence voltage induce negative sequence flux, not decaying.
Part of stator flux almost freeze during LVRT, decayin In g
Induced voltage at rotor terminal exceed DC link voltage, negative sequence induced rotor voltage can reach 3.5Vnom
Current control of converter are actually converting mechanical energy into DC link, similar to a synchronous generator in principle
Double frequency air-gap torque exists, increasing load of gearbox
Negative sequence voltage will be induced during the fault, and not decaying.
2018/11/6

15. Impact on Converter Design – Unbalanced Grid Fault
DFIG LVRT – Asymmetrical Fault
DFIG - Grid Low Voltage Ride Through
Rotor-side converter to conduct peak current of over 2 times nominal
Quick control of grid-side converter after transient
Rotor-side converter to conduct steady state negative sequence current, > nominal current dependent on control
Challenge in DC link control and current (reactive power) control, the crowbar will make the situation complex
Device rating and DC protection is always the key, and varying with control strategy.
2018/11/6

16. Impact on Converter Design – DFIG LVRT
Grid
Crowbar
Short connect rotor side converter (through resistors) to protect DC capacitor
Simple solution
Impact on DFIG control, especially when DFIG rotor shorted.
Increase gearbox loading
Grid
Brake Chopper
DFIG remain controlled
Extra switches & load resistors, increasing cost
Disconnect stator with grid
Results depending on stator current DC offset
Quick connection to grid after fault
Reduced reactive power capability during fault
Grid
Different strategy will have different impact on the converter design.
Impact on Converter Design
Topology
Device rating & cooling
Protection on over current – dynamic thermal model
DC link capacity
Typical Solutions for DFIG LVRT

17. Impact on Converter Design - Full Power Converter LVRT
Grid
Grid
Grid voltage fault
Full Power Converter - Grid Low Voltage Ride Through
Challenge
Transient current increases to around 2 time of nominal, and under control shortly
Generator energy going into DC link, when no energy going out to grid.
Improper control even introduce reverse energy into DC link from grid
Impact on converter design
Device rating and cooling
DC link capacity – transient of LVRT and unbalance grid operation
Brake chopper – response speed of generator side converter
Much simple situation. Two voltage source among an inductor. Quick response, transient large current, DC protection is the key.
2018/11/6

18. Requirements on IGBT modules -> Electrical
Due to high humidity in several countries and also additional high salt content in the air, the clearance and creepage distances of the modules are quite important and or splash water protected cabinet has to be used. Otherwise flash over occurs on the modules.
In case protected cabinets are not used, IHM and PrimePACK™ modules give the customer highest margins and are best solutions, especially for offshore turbines.
2018/11/6

19. Requirements to IGBT modules –IGBT Power Cycling
TChip
TDCB
TBaseplate
TCooler ×
Failure Mechanism
Heel Cracks
Bond Lift-off
Metallization Reconstruction
Wire Corrosion
Infineon Improvement
Material of Wires
Shape of Bonding Tools & Bonding Parameters
Metallization of Chip & Leads
Protective Coating

20. Requirements to IGBT modules – Electrical Limit
Diode SOA
IGBT RBSOA

21. Requirements to IGBT modules – Thermal Limit
IGBT Thermal Impedance
Diode Thermal Impedance
Temperature under switching
Thermistor inside IGBT module

22. Summary Requirement of IGBT modules for wind converter
20 years design-lifetime for power semiconductors
calculation based on load cycles given by customers based on their specific power conversion system.
Clearance and creepage distances higher than for industry inverters needed in case no splash water protected cabinet is used.
for high humidity and salt content in the air
Low losses
Low thermal resistances
Availability of DC-link voltage
Package, internal stray inductance.
RBSOA
2018/11/6

23. Solutions – EconoDUAL module~ - + C
G/E
NTC
“FF”
Inom
IGBT3 E3
IGBT4 E4
150A
FF150R17ME3G
225A
FF225R17ME3
FF225R17ME4
300A
FF300R17ME3
FF300R17ME4
450A
FF450R17ME3
FF450R17ME4
2018/11/6

24. Solutions – PrimePACK™
Highest creepage and clearance distance
Housing material with CTI>400
Designed for over voltage class 2
Very low inductive module design
Optimized chip position for better heat spreading.
Complete portfolio available for 1700V.
Easy for paralleling of several modules
Optimized driver board design possible
2018/11/6

25. Solutions – PrimePACK Product Range
New High Power Density IGBT :
FF1400R17IE4
2018/11/6

26. IHM B family with IGBT4 1200V/1700V FZ Single switch 3600 INOM 3600A
R17 UCE 1700 V
H IHM B housing
P4 High Power IGBT4
_B2 Traction version
NEW
New IHM B housing
New IGBT4 chip
2018/11/6

27. Products Range (1700V) “Copper base plate” “AlSiC base plate”
2018/11/6

28. IGBT modules ->Double Feed Wind System
Wind Power
IGBT Module
Rotor side
Paralleling/ per arm
Grid side
Paralleling
/Per arm
Cooling
1.25MW
EconoDUAL3
FF450R17ME4
2pcs
FS450R17ME4 N
Water
PrimePACK2/3
FF1000R17IE4
FF650R17IE4
1.5MW
3pcs
Air-forced
IHM B
IHM A
FZ1600R17HP4
FZ1600R17KE3
2.0MW
PrimePACK3
FZ2400R17HP4
4pcs
*Remark:
1) The proposal is based on the simulation conditions below as well as the general case experiences.
Vdc=1100V, Vin=690V, fo=0~15Hz, rotor side, fo=50Hz, grid side, OL=120%.
2) The usage of the different IGBT solutions are mostly influenced by the real cooling system. Therefore, the
disclaimer rule should be complied.
2018/11/6

29. IGBT modules ->Full Power Wind System
Wind Power
IGBT Module
Rotor side
Paralleling/ per arm
Grid side
Paralleling/Per arm
Cooling
1.5MW
EconoDUAL3
FF450R17ME4
7pcs
Water
PrimePACK3
FF1000R17IE4
3pcs
IHM A
FF1200R17KE3
2pcs
2.0MW
IHM B
FZ2400R17HP4_B29
8pcs
2018/11/6

30. Solar inverter and Infineon solution
Presentation title
Solar inverter and Infineon solution
2018/11/6
2018/11/6
Page 30

31. Efficiency is the key – Losses Chain in Solar inverter
Low losses on Semiconductor
EFFICIENCY
Low loss on filter
Low Power on colling system
Low loss on transformer

32. How to increase solar inverter efficiency?
HiPo
IGBT2 – DLC
IGBT3 – E3
total switching losses
IGBT2 – DN2
MePo
IGBT3 – T3
-15% Eoff
IGBT2 – KS4
LoPo
-20% Eoff
IGBT4 High Power: improved softness IGBT4 Medium Power: lower switching losses than E3 with the same softness
IGBT4 Low Power: lower switching losses than T3 with the same switching characteristic
Saturation voltage VCEsat [V]
LoPo - IGBT4 Low Power
Typical Tvj=125°C
MePo - IGBT4 Medium Power
HiPo - IGBT4 High Power for PrimePACK for Electric Vehicle
1200V IGBT chip for different application

33. 1200V Low Power IGBT4 Approx switching losses Eoff is reduced by 15% ;
Condition:
Turn-off process of IGBT4 vs.IGBT3 under untypical test for extremely high parasitics stray inductance;
(Ta=25°C, Inom=150A, Lδ=200nH, Vce=400V/450/500V)
/ us
T4 is slightly softer than T3;
Approx switching losses Eoff is reduced by 15% ;
2018/11/6

34. 1200V Medium Power IGBT4 Vdc=700V Vdc=800V IGBT3-E3 IGBT-E4
Condition: Softness Vs. Inom=300A (FF300R12XX)
Vdc=700V
Vdc=800V
IGBT3-E3
IGBT-E4
E4 is slightly softer than E3;
Switching losses Eoff is reduced by approx. 15% ;
2018/11/6

35. 1200V High Power IGBT4- Softness measurement
Condition:
Turn off characteristic for 2400A-Modules without active clamping control.
(Rg=0.3Ω, Io=1/2Inom, Tvj=25℃)
IGBT3
IGBT4
1200A
800V
1176V
1200A
250V
300V
P4 is softer than E3;
2018/11/6

36. How to increase solar inverter efficiency?
Typical curve Vcesat vs Tvj
Vdc=500V
I=213A
f=5kHz
m=0.88
IGBT
Diode
Static Loss
Dynamic Loss
FF200R12KE3
177
100 23 28
FF300R12KE3
142 92 21 35
FF400R12KE3
125 87 19 44
FF400R12KT3
119 73
FF450R12KT4
124 62 40
Static
Loss
Dynamic
Next
Better
Last best
Tvj
FF200R12KE3
177
100
100%
122
FF300R12KE3
142 92
85%
102
FF400R12KE3
125 87
91%
77%
91.4
FF400R12KT3
119 73
70%
87.4
FF450R12KT4
124 62
96%
67%
84.9
Typical curve Vcesat vs Tvj
More silicon lower loss, from 200A to 400A %
Low Tvj, Lower dynamic loss, from 122C to 91 C %
Fast IGBT3 lower dynamic loss %
IGBT4 is the Best-
---Pdym=62W
---Tvj-= 84.9 C
2018/11/6

37. FF400R12KE3 Eon & Eoff test at different temperature
Rgon/off=3.3Ω,Cge=0,Vge=+15V/-8V

38. How to increase solar inverter efficiency?
PrimePack™ parameter
66.5% less losses at 20kHz
Eon
Eoff
Erec Qr
FF600R12IE4 61 73
110 45
FF600R12IS4F 20 40 10
Vdc=500V
I=213A
m=0.88
FF600R12IE4
FF600R12IS4F
Total Loss
Tvj
10kHz
397
77.4
343
73.0
20kHz
668
101.6
444
93.0
Simulation
High speed IGBT2 +SiC diode
SW loss reduction by
SiC diode recovery process:
No storage charge Q
No recovery process
Ultra switching speed
Low recovery loss
2018/11/6
2018/11/6
Page 38

39. How to increase solar inverter efficiency?
From EconoDual™3 to PrimePack™
IGBT module
IGBT conduction loss (W)
IGBT
switching loss(W)
Rthjc
(per IGBT)
(k/W)
Diode conduction loss（W)
Diode switching loss(W)
(per Diode)
(k/w)
Rthch (per module) (k/W)
Rth
heatsink (per arm) (k/W)
Total loss
(W) Tj
(C)
FF450R12ME4
113
105
0.066 21 41
0.1
0.009
0.2
280
125.4
FF450R12IE4
110 90
0.059 20 35
0.105
0.0045
255 84
Vdc=500v, Irms=234A, fsw=4.8KHz,with Rgon/off=2.5/3.1Ω
Bigger footprint, lower thermal resistance---lower junction temperature
Lower temperature lower conduction loss and switching loss
2018/11/6

40. How to increase solar inverter efficiency?
Using 3-Level instead of 2-level
NPC 3-Level
T type 3-level

41. How to increase solar inverter efficiency?
NPC 3-level and 2 level loss comparison
Spec:Vdc=800V,Vout=270V, Irms=106A,Po=50kVA
5KHz
10KHz
15KHz
20KHz
30KHz
3 pcs FF300R12KT4 Loss(tot)
990W
1626W
2262W
2892W
3528W
3 pcs F3L300R07PE4 Loss(tot)
879W
1049.8W
1220.8W
1391.8W
1562.8W
Losses reduced
by 50%
Cost
Output inductance: 50% Lower
Driver board: doubled
Loss:
Losses reduced by 50% at 20kHz
Smaller filter chokes lower Loss
Can achieve lower system loss
2018/11/6

42. How to increase solar inverter efficiency?
T type 3-level and NPC 3-level loss comparison
Spec:Vdc=800V,Vout=270V, Irms=106A,Po=50kVA
5KHz
10KHz
15KHz
20KHz
30KHz
3 pcs FF300R12KT4 and FF300R06KE3 Loss(tot)
732W
943W
1155W
1366W
1788W
3 pcs F3L300R07PE4 Loss(tot)
812W
991W
1170W
1349W
1706W vs
FF300R12KT4 & FF600R06KE3
62mm package
F3L300R07PE4
EconoPACK4 package
T type 3-level advantage
higher efficiency at 10-12KHz
T type 3-level disadvantage
Higher Power semiconductor cost
More complex in control
2018/11/6

43. FF600R12ME4 A real 600A module and the new best-in-class
*based on target data sheets

44. FF450R12ME4 vs.FF600R12ME4 in 100kw solar inverter
IGBT module
IGBT conduction loss (W)
IGBT
switching loss
(W)
Rthjc
(per IGBT)
(k/W)
Diode conduction loss（W)
Diode switching loss(W)
(per Diode)
(k/w)
Rthch (per module) (k/W)
Total loss Tj
(C)
FF450R12ME4
116 72
0.066 26 54
0.1
0.009
1608 87
FF600R12ME4
107 80
0.041 23 56
0.067
1596
Vdc=480v, Irms=213A, fsw=4.8KHz
Nearly 38% lower Rthjc
7℃ Tj lower
2018/11/6

45. What´s next? SiC JFET enabling a path towards 99% efficiency…
2018/11/6

46. Solutions – Easy Family
Key Features
IGBT4 Low Power Chip
Switching Loss
- 20% lower than T3 chip
- 32% lower than E3 chip
Pin Grid for maximum flexibility
- 89 pins/ 165 pins
- SixPack, H-Bridge,
- Boost +H-Bridge,
- Three Level
- Patented customized module…….
Tvjmax=175  C
PressFIT available
Typical Design:
F4-30R06W1E3 =>3KW
F4-50R06W1E3 =>4KW
F4-75R06W1E3 =>5KW

47. Solutions – Easy2B_Three Level
Key Features
Three level arm with full size diode
650V chip
-Lower on-state loss 1.45V IGBT
1.55V diode
-Lower switching losses
-Soft Switch off
-75A,100A,150A
Low stray inductance and
Soft Chip
-Extended RBSOA
-For Higher DC link voltage
Tvjmax=175  C
PressFIT
Typical Design:
F3L75R07W2E3_B11 =>15KW
F3L100R07W2E3_B11 =>20KW
F3L150R07W2E3_B11 =>25KW

48. Solutions – EconoPack™4
Key Features
Three level arm with full size diode
650V chip
-Lower on-state loss 1.45V IGBT
1.55V diode
-Lower switching losses
-Soft Switch off
-200A 300A
Low stray inductance and
Soft Chip
-Extended RBSOA
-For Higher DC link voltage
Tvjmax=175  C
PressFIT
Typical Design:
F3L200R07PE4 =>30-40KW
F3L300R07PE4 =>50-70KW

49. Solutions – EconoDUAL™3
Key Features
225A-600A, 600V,1200V
Real 600A module with 22% lower Rthjc
Copper bonding 47% more current
High Efficiency
Tvjmax=175  C
PressFIT
Typical Design:
FF300R12ME4 =>50kW
FF450R12ME4 =>100kW
FF600R12ME4 =>100kW

50. Solutions – PrimePACK™
Key Features
IGBT4
- Medium power chip
- High power chip
- SiC Diode without Qr
Very low stray inductance by internal laminate bus
-Extended RBSOA
-For High Speed Chip
-Low Rg, Switch IGBT faster
Tvjmax=175  C
Application
Solar Inverter
UPS
Typical Design:
FF600R12IE4 =>100kW
FF1400R12IE4 =>250kW
FF1400R12IE4*2 =>500kW

51. Solutions – Product Portfolio – STACK
IGBT Stacks Series ModSTACKTM
Up to 1700V DC
Up to 2400A DC
Water or Air cooled
Intelligent Power Modules Series PrimeSTACKTM
Up To 1700V DC
Up To 1600A DC
IGBT Stacks series LightSTACK
Up to 3000A DC

52. STACK solution for 100KW solar inverter ----6PS0400R12KT3-3GH-V
400A Icnom, will run up 120KW solar inverter
OV,OC,OT protection
9.9kg; 280*216*165mm
Quick design for customer
With capacitors and fan optional

53. STACK solution for 250KW solar inverter ----3
STACK solution for 250KW solar inverter ----3* 2PS1600R12KE3-CGH-CxVB1B2B3
1600A Icnom, will run up 250KW solar inverter
OV,OC,OT protection
100kg; 1142*468*313mm
Quick design for customer