Description:

The ABB 5SHY3545L0016 3BHB020720R0002​ is a high-performance, medium-voltage Insulated Gate Bipolar Transistor (IGBT) power module engineered by ABB for the most demanding industrial drive systems. It serves as the critical power conversion heart within ABB’s medium-voltage drive platforms, such as the ACS800 MV series, transforming electrical power with exceptional efficiency and reliability to control high-power motors, compressors, and pumps.

Application Scenarios:

At a massive open-pit mining operation, the main overland conveyor system—a 3-kilometer lifeline transporting thousands of tons of ore per hour—was plagued by frequent, catastrophic drive failures. Each unplanned shutdown cost over $100.000 per hour in lost production. The root cause was the existing power modules’ inability to handle the immense electrical stress and thermal cycling from constant start-stop cycles under heavy load. The engineering team spearheaded a drive modernization project, replacing the legacy power stages with the ABB 5SHY3545L0016 3BHB020720R0002​ modules. The module’s robust 3300V/1200A rating effortlessly managed the conveyor’s peak demands, while its advanced trench-gate field-stop (TFS) IGBT technology reduced switching losses by 30%, lowering heat generation. More importantly, its rugged construction and wide operating temperature range (-40°C to +125°C junction) withstood the site’s dust, vibration, and temperature extremes. Post-upgrade, the conveyor system achieved 18 months of continuous operation without a single power module failure, transforming maintenance from reactive firefighting to proactive planning and saving millions in avoided downtime. This case exemplifies the 5SHY3545L0016 3BHB020720R0002’s role in solving the core industrial challenges of extreme reliability, energy efficiency, and total cost of ownership in mission-critical material handling.

Technical Principles and Innovative Values:

Innovation Point 1: Trench-Gate Field-Stop (TFS) IGBT Technology for Unmatched Efficiency.​ The 5SHY3545L0016 3BHB020720R0002​ utilizes ABB’s proprietary TFS IGBT chips. Unlike conventional planar IGBTs, the trench-gate structure provides a more efficient electron path, while the field-stop layer allows for a thinner wafer. This combination reduces saturation voltage (Vce(sat)) and, crucially, cuts switching losses by up to 30% . For a medium-voltage drive powering a 6MW induced draft fan, this translates directly to a 5-8% reduction in annual energy consumption, a saving that can exceed $50.000 per year per drive.

Innovation Point 2: Advanced Press-Fit Package for Superior Thermal Management and Reliability.​ The module employs a press-fit contact system and direct copper bonding within its ISOPLUS™ package. This design eliminates solder fatigue—a common failure mode in power cycling applications—and dramatically enhances thermal conductivity. The low thermal resistance (0.015 K/W) ensures heat is rapidly transferred from the silicon junction to the heatsink, allowing the module to operate at higher power densities and with a longer service life, often exceeding 10 years in continuous duty .

Innovation Point 3: Integrated Diagnostics for Predictive Health Management.​ Beyond raw power handling, the module is designed for the modern, connected plant. It incorporates built-in temperature and voltage sensors at critical points. This data can be fed to monitoring units (like the ABB CM-MPS) to provide real-time health analytics . Engineers can track junction temperature trends, identify early signs of cooling degradation, or detect abnormal voltage spikes, enabling predictive maintenance and transforming unplanned failures into scheduled interventions.

Application Cases and Industry Value:

Case Study 1: Cement Plant Kiln Fan Drive Optimization.​ A major cement producer in Asia retrofitted its 11kV kiln exhaust fan drives with new power cabinets centered on the ABB 5SHY3545L0016 3BHB020720R0002. The fan, critical for kiln atmosphere control, previously suffered from poor speed regulation and high harmonic distortion. The new modules, with their high switching frequency capability, enabled a cleaner sinusoidal output current. This improved motor performance and reduced stress on the plant’s electrical network. The plant’s energy manager reported, “The precision control and efficiency of the 5SHY3545L0016​ modules allowed us to run the fan at the optimal speed for each production phase. Our specific energy consumption for clinker cooling dropped by 7%, and power factor penalties were eliminated.”

Case Study 2: Offshore Gas Compression Platform.​ On a North Sea platform, space and reliability are at a premium. A critical gas export compressor was driven by an aging MV drive system due for replacement. The new drive design specified the ABB 5SHY3545L0016 3BHB020720R0002​ for its compact power density and proven maritime qualifications. The module’s robust isolation (4.5kV) was crucial for the salty, humid environment. During commissioning, the drive provided exceptionally smooth torque control, eliminating damaging torsional vibrations during start-up. The platform’s lead electrical engineer noted, “We needed a power module we could trust for a decade without easy access for replacement. The 5SHY3545L0016’s design-for-reliability and ABB’s support gave us that confidence.”

Related Product Combination Solutions:

The ABB 5SHY3545L0016 3BHB020720R0002​ is the cornerstone of a complete power conversion solution. Key synergistic products include:

ABB 5SHY3545L0017 3BHB020721R0002:​ A higher-current variant (1500A) within the same series, used for parallel configurations or drives above 3MW .

ABB 5SHY3545L0015 3BHB020719R0002:​ A lower-current variant (1000A) for applications with moderate power requirements, maintaining the same footprint and efficiency .

ABB ACS800 MV Drive Platform:​ The premier medium-voltage drive system that integrates the 5SHY3545L0016 3BHB020720R0002​ as its standard or optional power stage .

ABB 3BHB020722R0001:​ A dedicated, optimized heatsink designed for maximum thermal dissipation from the 5SHY3545L0016​ module, ensuring peak performance and longevity .

ABB 3BHB020723R0001:​ A matched gate driver board that provides the precise, isolated control signals required to switch the IGBT chips efficiently and safely .

ABB 5SDF06H4500:​ A higher-voltage (4.5kV) IGBT module for drive systems operating at 11kV-13.8kV, representing the next step up in the voltage range .

ABB CM-MPS (Condition Monitoring for Modular Power Supplies):​ A monitoring unit that connects to the module’s diagnostic outputs, enabling predictive maintenance and integration into plant asset management systems .

Installation, Maintenance, and Full-Cycle Support:

Proper installation begins with rigorous preparation. Verify the target drive’s voltage and current ratings match the 5SHY3545L0016 3BHB020720R0002​ module’s specifications. Ensure the mounting surface (heatsink) is clean, flat, and coated with the correct thermal interface material. Strict electrostatic discharge (ESD) procedures must be followed during handling. The module is secured via its press-fit pins or mounting screws with a specified torque to ensure optimal thermal contact. Electrical connections must be made with appropriately sized, high-quality cables, and all busbar joints must be torqued to specification to prevent hot spots.

Routine maintenance is focused on monitoring rather than physical intervention. The primary task is to observe the module’s health through integrated diagnostics via the drive’s HMI or connected monitoring system. Periodically inspect the cooling system (fans, filters, water flow) for the external heatsink, as thermal management is paramount. Visually check for any signs of contamination, corrosion, or loose connections during planned outages. If a fault is indicated, module replacement should be performed by qualified personnel. In many drive designs, the modular nature allows for replacement with minimal downtime.

We provide end-to-end lifecycle support for the ABB 5SHY3545L0016 3BHB020720R0002. From initial system design and power stage selection to 24/7 technical support and guaranteed supply of authentic, factory-tested spare parts, our expertise ensures your drive system’s integrity. We assist with legacy system upgrades, performance optimization, and comprehensive predictive maintenance programs to maximize your asset’s uptime and return on investment.