ABB 5SHY35L4520 5SXE10-0181 AC10272001R0101

Description

Product Description
The ABB 5SHY35L4520 also identified by alternate part numbers 5SXE10-0181 and AC10272001R0101, is a high-power, press-pack Integrated Gate-Commutated Thyristor (IGCT) semiconductor. It is a core component within ABB’s medium-voltage drive power stacks, such as those used in the ACS 6000 and ACS 6080 series. This specific IGCT is a symmetrical or reverse-conducting type, meaning it integrates the main thyristor and an anti-parallel diode into a single, robust silicon wafer within the same press-pack housing. The ABB 5SHY35L4520 is engineered for exceptional efficiency and ruggedness in the most demanding high-power conversion applications. Its integrated design simplifies the power cell assembly and ensures perfect electrical matching between the switch and diode. The operational reliability and efficiency of the entire multi-megawatt drive hinge on the performance of these key semiconductors. Proper selection, handling, and pairing with its dedicated gate driver unit are critical for the 5SHY35L4520 to function as designed. The ABB 5SHY35L4520 represents a pinnacle of power semiconductor technology for heavy industry.

Product Parameters

• Component Type: Reverse-Conducting / Symmetrical Integrated Gate-Commutated Thyristor (RC-IGCT).

• Voltage Rating: High blocking voltage, typically 4500V, 5500V, or 6500V.

• Current Rating: High controllable on-state current, with high surge current capability.

• Structure: Monolithic integration of a GCT and an anti-parallel diode on a single silicon chip within one package.

• Package: Standard Press-Pack (Hockey Puck) style, requiring precise mechanical clamping.

• Gate Unit: Must be operated with its specific, matched Gate Driver Unit (GDU), which provides the high-power gate current pulse for turn-on and turn-off.

• Switching Characteristics: Features hard-driven turn-off, enabling snubberless or low-snubber operation in properly designed circuits.

Advantages and Features

• Monolithic Integration: The single-chip design of the ABB 5SHY35L4520 eliminates the separate diode component, reducing the number of parts in the stack, simplifying assembly, and improving reliability by ensuring perfect thermal and electrical matching of the switch and diode.

• Ultra-Low Conduction Losses: Exhibits an extremely low forward voltage drop in both the thyristor and diode regions, maximizing efficiency, especially in high-current applications, and reducing cooling requirements.

• Unmatched Ruggedness: Exceptionally robust against high di/dt, dv/dt, and short-circuit events, providing inherent reliability for critical industrial processes.

• Compact Power Density: The integrated design and press-pack cooling enable a very high power density, contributing to a smaller overall drive footprint.

• Simplified Circuit Design: The hard-driven turn-off and integrated diode can allow for simplified snubber circuits or even snubberless operation in some topologies, increasing overall system reliability.

• Proven in Mission-Critical Applications: The backbone technology for multi-megawatt drives where uptime and efficiency are paramount.

Application Cases in Various Fields

• Metals Industry (Primary Metals): Used in the inverter sections of reversing rolling mill drives and mine hoists, where the ABB 5SHY35L4520 handles extreme power levels and frequent regenerative braking.

• Mining (Gearless Mill Drives – GMDs): A fundamental component in the low-speed synchronous motor drives for SAG and ball mills, where its robustness ensures continuous operation under the most punishing loads.

• Marine Propulsion (Large Vessels & Icebreakers): Powers the main propulsion drives, providing the high torque and reliability needed for dynamic maneuvering and heavy loads.

• Energy (Large Pump & Fan Drives, Pumped Storage): Used in very high-power compressor and pump drives, as well as in variable-speed applications for grid stability and energy storage.

• Test Facilities for Heavy Equipment: Essential in high-power, four-quadrant test benches used to validate large motors, generators, and turbines.

Comparison with Competing Products

• Vs. Asymmetric IGCT + Separate Diode (e.g., 5SHX + 5SHY): The <a href=”https://new.abb.com/products/5SHY35L4520″ target=”_blank”>ABB 5SHY35L4520</a> integrates both functions. This offers advantages in part count and guaranteed matching but provides less flexibility. The asymmetric+diode approach allows independent optimization or replacement of the diode.

• Vs. High-Voltage IGBT Modules (e.g., from Infineon, Mitsubishi): Competing IGBT technologies offer higher switching frequencies. The 5SHY35L4520 IGCT excels in the highest power ranges (>10+ MW) where its ultra-low conduction losses dominate overall system efficiency. The choice is a fundamental architectural decision of the drive platform.

• Vs. Other IGCT Manufacturers (e.g., GE-SSR): The primary competition is at the system (drive) level, not the component level. The ABB 5SHY35L4520 is designed for ABB’s specific mechanical and electrical ecosystem (GDUs, snubbers, cooling) and is not interchangeable with other brands’ IGCTs.

Selection Suggestions and Precautions

1. Exact Part Number Verification: Use all listed part numbers (5SHY35L4520, 5SXE10-0181, AC10272001R0101) to confirm the correct component for your specific drive model, series, and power cell position. Cross-reference with the official drive manual.

2. Mandatory GDU Match: The IGCT must be used with its specifically designated Gate Driver Unit (GDU). Using an incorrect GDU will result in improper switching, excessive losses, and immediate device failure.

3. Replace as Part of a Full Phase Leg Analysis: An IGCT failure is a major event. It necessitates a thorough inspection of the entire phase leg: the opposite switch/diode pair, snubbers, DC-link capacitors, gate drive power supplies, and the cooling system. Root cause must be identified.

4. Specialist Installation Required: Installation demands a clean environment, specific thermal interface material (often a phase-change pad or paste), and a calibrated tool to apply the exact tonnage of clamping force. Improper force is a leading cause of early failure.

5. Cooling System Paramount: Prior to installation, the water cooling system’s flow, pressure, temperature, and especially conductivity must be rigorously checked and be within ABB’s strict specifications. Poor coolant quality can cause galvanic corrosion and failure.

6. Exclusive OEM Sourcing and Expert Service: This component must be purchased from ABB or an authorized distributor and installed by ABB-certified field service engineers. The risks of using non-genuine parts or unqualified personnel include catastrophic failure of the power cell, extended downtime, and severe safety hazards due to the immense stored energy.

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