ABB 5SHY35L4520 Phase-Controlled SCR Stack – Designed for Cycloconverters & Static VAR Compensators

Description

Application Scenarios

At an aluminum smelter in Canada, a 120 MW rectifier system uses over 200 ABB 5SHY35L4520 thyristors to convert AC grid power into low-voltage, high-current DC for electrolytic cells. During a summer heatwave, ambient temperatures exceeded 40°C, yet the plant maintained full production—thanks to the 5SHY35L4520’s efficient water-cooling interface and stable forward voltage drop (<1.8 V). When one unit failed due to a cooling leak, maintenance replaced it within 2 hours using standard hydraulic pressing tools, avoiding a $ 1.2M/hour production halt. In this extreme environment, the ABB 5SHY35L4520 isn’t just a component—it’s the heartbeat of continuous metallurgical operation.

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Technical Principles and Innovative Values

Innovation Point 1: Double-Sided Water Cooling for Ultra-Low Thermal Resistance

The ABB 5SHY35L4520 features integrated copper cooling plates on both top and bottom, enabling heat flux densities exceeding 20 W/cm². This allows sustained operation at full load in compact converter cabinets—critical for space-constrained retrofits.

Innovation Point 2: Press-Pack Design Eliminates Wire Bonds

Unlike traditional bolted thyristors, the press-pack construction uses solid metal interfaces instead of fragile wire bonds, dramatically improving resistance to thermal cycling fatigue and short-circuit stress—extending service life by 3–5×.

Innovation Point 3: Low Internal Inductance for Fast Switching

Optimized internal layout minimizes stray inductance (<20 nH), reducing voltage overshoot during turn-off and enabling reliable series/parallel stacking without snubber networks in many applications.

Innovation Point 4: Built-In Gate- Cathode Protection

Integrated gate-cathode resistor network prevents false triggering from dv/dt transients—a common issue in high-di/dt industrial environments like arc furnaces or mine hoists.

Application Cases and Industry Value

In a European railway traction substation, ABB 5SHY35L4520 thyristors form the core of a 16.7 Hz cycloconverter feeding overhead catenary lines. Despite daily load swings from 0 to 100% and frequent lightning-induced surges, the system has operated continuously for over 12 years with zero thyristor failures—attributed to the module’s rugged press-pack design and high surge rating.

Similarly, in a Middle Eastern gas compressor station, 5SHY35L4520 units enable a 50 MVAR static VAR compensator (SVC) to stabilize grid voltage during compressor startups. The fast phase control response (<10 ms) prevents voltage sags that previously tripped sensitive instrumentation—enhancing overall plant resilience.

Related Product Combination Solutions

ABB 5SHX1445H0002: Gate drive unit (GDU) optimized for 5SHY-series thyristors

ABB 5SNA1445H0001: Snubber capacitor/resistor kits for series-connected stacks

ABB HVC/SVC Control Systems: Legacy ABB controllers (e.g., PSC600) for thyristor-based compensation

ABB Water Cooling Units (WCU): Closed-loop deionized water systems with conductivity monitoring

ABB 5SHY35L4510: Lower-current variant (3500 V / 3000 A) for smaller rectifiers

ABB 5SHY40L5020: Higher-rating successor (4000 V / 5000 A) for next-gen systems

ABB Hydraulic Press Tools: Specialized fixtures for safe installation/removal

ABB Condition Monitoring Sensors: Fiber-optic temperature and leakage current sensors for predictive maintenance

These components support full lifecycle management—from initial commissioning to end-of-life replacement.

Installation, Maintenance, and Full-Cycle Support

Installing the ABB 5SHY35L4520 requires a calibrated hydraulic press tool to apply precise clamping force (typically 120–150 kN) and ensure uniform contact pressure across the cooling interfaces. Incorrect mounting can lead to hot spots or premature failure. Always use deionized water (conductivity <0.5 µS/cm) in the cooling loop to prevent electrical leakage.

For maintenance, periodic inspection of cooling plate integrity, gate connections, and thermal paste condition is recommended. While the thyristor itself has no moving parts or consumables, surrounding components (snubbers, fuses, GDUs) should be checked annually in high-stress applications.

We supply only factory-new surplus, refurbished, or tested-used ABB 5SHY35L4520 units, each accompanied by:

Full electrical test report (VDRM, IGT, VT)

Visual inspection certificate

Mounting torque and cooling specs

Cross-reference to modern equivalents (e.g., Infineon/IXYS alternatives)

Our engineering team provides remote support for gate drive compatibility, thermal modeling, and failure analysis—ensuring your high-power system remains operational, safe, and efficient.

Contact us for emergency spares, bulk procurement, or migration planning. Whether you’re sustaining a 30-year-old HVDC link or upgrading an industrial drive, the ABB 5SHY35L4520 delivers proven performance when it matters most.