DF200AC160 SanRex 1600V 200A Fast Recovery Diode Module

Content last revised on November 19, 2025

Sanrex DF200AC160 Three-Phase Diode Rectifier Module: Engineering Review

The Sanrex DF200AC160 is a high-reliability three-phase diode bridge rectifier, engineered for robust performance in demanding power conversion systems. Delivering a potent combination of a 1600V repetitive peak reverse voltage (VRRM) and a 200A average forward current (IF(AV)), this module is optimized for mechanical and thermal synergy in modern power designs. Its key advantages lie in a very low forward voltage drop and an exceptionally high surge current capability. These attributes directly address the engineering need for both high operational efficiency and system survivability during fault conditions. For power systems requiring robust front-end rectification, such as industrial motor drives or high-power battery chargers, the DF200AC160's high surge rating provides critical resilience against line disturbances and inrush currents. For applications operating on lower voltage lines, the related DF200AA160 offers similar current handling capabilities with a different voltage rating.

Key Parameter Overview

Decoding the Specs for System Integration and Robustness

The technical specifications of the DF200AC160 are tailored for high-power industrial applications. The 1600V VRRM rating provides a substantial safety margin for systems operating on 480V to 690V AC lines, while the 200A current rating supports significant power throughput. A critical parameter for reliability is the I²t rating of 17,000 A²s, which quantifies the module's ability to withstand non-repetitive surge events, simplifying fuse coordination and enhancing overall system protection. The low-profile 17mm case height is a key design feature that facilitates parallel connection with other power modules, such as IGBTs, enabling streamlined, low-inductance bus bar designs.

Download the DF200AC160 datasheet for detailed specifications and performance curves.

Application Scenarios & Value

System-Level Benefits in Industrial Power Rectification

Best Fit: For three-phase power supplies over 100kW requiring robust front-end rectification with simplified mechanical assembly, the DF200AC160 is a premier choice due to its high surge capability and low-profile design. This module excels as the front-end rectifier in a wide range of industrial equipment. Consider a high-frequency Welding Power Supply, where input line stability can be unpredictable. The DF200AC160's impressive 2000A surge forward current (IFSM) rating provides a critical defense mechanism. This is not just a number; it represents the module's ability to absorb massive, short-duration energy spikes—like those from utility switching events or nearby heavy load startups—without failing. This high surge immunity translates directly into higher equipment uptime and reduced field service costs. Its robust nature also makes it ideal for uninterruptible power supplies (UPS), large-scale battery charging systems, and the input stage of high-power Variable Frequency Drives (VFDs) used in motor control.

Frequently Asked Questions (FAQ)

What is the primary benefit of the 17mm low-profile case design?
The 17mm case height allows for direct and level co-mounting with standard-profile IGBT and MOSFET modules. This simplifies the mechanical layout of the power assembly, reduces the complexity of bus bars, and helps minimize stray inductance, which is crucial for improving efficiency and reducing EMI in high-frequency power converters.

How does the 2000A surge current rating impact system design?
The high surge current capability allows the module to safely handle significant inrush currents during startup and to withstand transient overcurrent events from the AC line without degradation. This robustness can simplify the selection of protective devices like fuses and circuit breakers, leading to a more reliable and cost-effective overall system design.

Is the mounting base of the DF200AC160 electrically isolated?
Yes, the module features an isolated mounting baseplate with an isolation voltage (VISO) rating of 2500V (RMS for 1 minute). This eliminates the need for external insulating materials between the module and the heatsink, simplifying thermal design, reducing assembly time, and improving heat transfer efficiency.

Can the DF200AC160 be used in applications higher than 200A?
While the module is rated for 200A, its design explicitly "enables easy parallel connection". Engineers can connect multiple DF200AC160 modules in parallel to achieve higher output current capacity, making it a scalable solution for very high-power systems.

What does the VRRM of 1600V mean for a 480V AC system?
A 480V nominal AC line can experience peak voltages of approximately 679V (480V * √2). The 1600V VRRM provides a safety factor of over 2.3x, which is a very robust design margin. This high margin ensures reliable operation even with significant voltage transients and swells on the AC line, a common occurrence in industrial environments.

Industry Insights & Strategic Advantage

Meeting the Demands for Power Density and Reliability

The design of the Sanrex DF200AC160 directly addresses two persistent trends in industrial power electronics: increasing power density and uncompromising reliability. As systems like industrial motor controls and power supplies become more compact, the ability to integrate components seamlessly becomes paramount. The module's low-profile 17mm package is a strategic design choice that facilitates denser power assemblies. By allowing the rectifier stage to share the same physical plane as the inverter's IGBTs, designers can create more compact, efficient, and cost-effective converters. This integration also contributes to enhanced reliability by minimizing the length and complexity of electrical connections, thereby reducing potential points of failure and improving thermal performance across the entire power stage.