IXYS DSSX110 Retrofit-Ready Schottky Rectifier for DSSX Series Control Systems
The IXYS DSSX110 is a high-performance Schottky rectifier module engineered for seamless integration into legacy and modern industrial control systems. Rated at 10A forward current and 100V reverse voltage in the industry-standard SOT-227B package, the DSSX110 is the preferred retrofit and upgrade solution for engineers replacing discontinued or aging DSSX-series components — including the DSSX16, DSSX28, DSSX60, and DSSX85 — without requiring redesign of the existing power stage or control cabinet layout.
In industrial retrofit projects, the DSSX110 is commonly deployed in DC bus rectification stages, freewheeling diode circuits, and snubber networks within drive cabinets, motor control centers, and distributed power supply units. Its low forward voltage drop and fast reverse recovery characteristics make it a reliable drop-in candidate for systems originally designed around earlier IXYS DSSX-family modules, preserving thermal management geometry and PCB footprint compatibility.
When planning a retrofit around the DSSX110, engineers must verify the existing power supply rail capacity — particularly where the original DSSX60 or DSSX85 was operating near its rated current ceiling. The DSSX110’s 10A continuous rating is well-suited for control-voltage rectification in PLC power supply modules, servo amplifier input stages, and auxiliary bus circuits. Confirm that the existing heatsink interface and mounting torque specifications align with the SOT-227B package requirements before installation.
Terminal wiring compatibility is a critical checkpoint. The SOT-227B package uses a standardized three-terminal layout (anode, anode, cathode), which is mechanically and electrically compatible across the DSSX series. However, engineers should inspect the existing terminal block assignments and bus bar connections within the control cabinet to ensure polarity and current path integrity are maintained during the swap. In systems using IXYS MCC26 or MCC44 thyristor modules on the same bus, the DSSX110 can be integrated without disrupting the existing SCR firing sequence or gate drive logic.
For systems migrating from older rectifier assemblies to a modernized power architecture, the DSSX110 pairs naturally with IXYS VUO series three-phase bridge rectifier modules and IXYS VHFD series fast recovery diode modules in the same control cabinet. Where the original design used discrete diode stacks, consolidating to the DSSX110’s compact SOT-227B format reduces wiring complexity and improves thermal uniformity across the power stage.
In communication-intensive retrofit scenarios — such as upgrading a legacy PROFIBUS-based motor drive system to PROFINET or EtherNet/IP — the DSSX110 supports the power supply integrity required by the new communication interface cards. Ensuring stable DC bus voltage during protocol migration is essential, particularly when the control system simultaneously hosts Siemens ET 200SP distributed I/O modules or Phoenix Contact Axioline F I/O terminals that depend on a clean 24VDC auxiliary rail.
Backplane and rack compatibility should also be confirmed during retrofit planning. In systems using Allen-Bradley 1756 ControlLogix or Siemens S7-300 chassis, the auxiliary power supply feeding the backplane often routes through a rectifier stage where the DSSX110 can serve as a direct replacement for a failed or end-of-life component. Module address assignments and I/O mapping in the PLC program are unaffected by the rectifier replacement, as the DSSX110 operates transparently within the power supply subsystem.
HMI screen integrity and SCADA data continuity are preserved during a DSSX110 swap because the replacement does not alter any signal-level wiring or communication link. Engineers can perform the replacement during a scheduled maintenance window without modifying WinCC, FactoryTalk View, or Ignition HMI configurations. Post-installation, a functional test of the DC bus voltage under load — using a calibrated clamp meter or the drive’s built-in diagnostics — confirms correct rectifier operation before returning the system to production.
Field commissioning of the DSSX110 follows a straightforward sequence: isolate the control cabinet, discharge bus capacitors, remove the legacy module, clean the heatsink contact surface, apply thermal compound, mount the DSSX110 to the specified torque, reconnect terminals, and perform a no-load power-on test before restoring full production load. This process typically completes within 30–60 minutes, minimizing unplanned downtime and supporting the goal of maintaining continuous production line availability.
Every DSSX110 unit supplied by SMARTNEXMSK is sourced from verified supply channels, undergoes pre-shipment functional testing, and is covered by a 12-month warranty against manufacturing defects. Stock is maintained for immediate dispatch to support urgent breakdown recovery and planned maintenance schedules alike.
Upgrade Compatibility Table
| Parameter | DSSX110 (Replacement) | DSSX60 / DSSX85 (Legacy) | Notes |
|---|---|---|---|
| Package | SOT-227B | SOT-227B | Direct mechanical fit; no bracket modification required |
| Forward Current (IF) | 10A | 6A / 8.5A | DSSX110 provides headroom for derating in high-ambient environments |
| Reverse Voltage (VRRM) | 100V | 100V | Identical voltage class; no bus voltage recalculation needed |
| Terminal Layout | A-A-K (SOT-227B standard) | A-A-K (SOT-227B standard) | Wiring polarity preserved; no rewiring required |
| Mounting Torque | 1.5–2.0 N·m | 1.5–2.0 N·m | Use calibrated torque driver; apply thermal compound |
| Communication Compatibility | Transparent (power stage only) | Transparent (power stage only) | No impact on PROFIBUS, PROFINET, EtherNet/IP, or Modbus links |
| Replacement Recommendation | Direct drop-in for DSSX16/28/60/85 | — | Confirm heatsink surface condition before installation |
| Commissioning Checkpoint | DC bus voltage under load | — | Verify with clamp meter or drive diagnostics post-installation |
| Warranty | 12 Months | — | Covers manufacturing defects; pre-shipment tested |
Retrofit Planning for Existing Automation Systems
A successful DSSX110 retrofit begins with a thorough audit of the existing control cabinet. Engineers should document the current power supply topology, identifying all rectifier positions and their associated load circuits. In a typical drive cabinet, the DSSX110 may replace a failed unit in the auxiliary 24VDC supply feeding Siemens S7-1200 or S7-1500 CPU modules, WAGO 750-series I/O couplers, or Beckhoff EK1100 EtherCAT couplers. The compact SOT-227B footprint ensures the replacement fits within the original DIN rail or panel-mount assembly without requiring additional space allocation.
Where the original system used a multi-module rectifier bank — for example, combining the DSSX85 with an IXYS VHFD14 fast recovery module for freewheeling duty — the DSSX110 can replace the Schottky stage while the VHFD14 remains in service, preserving the existing thermal and electrical balance of the power stage. Engineers should also inspect the associated IXYS SKKD 42 or similar dual diode modules in the same rectifier assembly to assess whether a broader preventive replacement is warranted during the same maintenance window.
For systems incorporating Omron CJ2M or Mitsubishi MELSEC Q-series PLCs with dedicated power supply modules, the DSSX110 supports the rectifier stage within the external 24VDC power supply unit. Verifying the power supply’s output ripple specification after DSSX110 installation ensures the PLC’s CPU and I/O modules receive clean, stable power — a prerequisite for reliable program execution and accurate analog I/O readings.
Programming cable compatibility and HMI communication links are unaffected by the DSSX110 replacement. Engineers can maintain live connection to the PLC via USB-SC09-A or PC Adapter USB A2 programming cables throughout the replacement process, monitoring system status in real time and confirming normal operation immediately after power restoration.
Downtime Control During System Migration
Minimizing production downtime during a DSSX110 retrofit requires advance preparation and a disciplined execution sequence. Before the maintenance window opens, engineers should pre-stage the replacement DSSX110 module, thermal compound, calibrated torque driver, and a DC bus discharge resistor. A pre-written commissioning checklist — covering isolation, discharge, installation, and functional test steps — reduces the risk of procedural errors under time pressure.
Where the control system architecture permits, a hot-standby power supply arrangement can maintain 24VDC auxiliary power to the PLC rack and I/O modules during the rectifier replacement, preserving program execution and communication link continuity. In systems without redundant power paths, the PLC program state should be saved to non-volatile memory (retentive data areas or memory cards) before isolation, ensuring that production recipes, setpoints, and counters are restored immediately upon power restoration without manual re-entry.
Post-installation, a structured functional test sequence — no-load power-on, bus voltage measurement, partial load test, and full production load restoration — confirms DSSX110 performance before releasing the system to operations. This phased approach protects the original program logic, preserves HMI screen data integrity, and maintains communication link continuity across PROFIBUS, PROFINET, or EtherNet/IP networks connected to the control system.
Retrofit Support FAQ
Q1: Is the IXYS DSSX110 a direct replacement for the DSSX60 and DSSX85?
Yes. The DSSX110 shares the SOT-227B package, identical terminal layout, and the same 100V reverse voltage class as the DSSX60 and DSSX85. Its higher 10A forward current rating provides additional thermal headroom, making it a preferred upgrade choice for systems operating in elevated ambient temperature environments. No mechanical modification or wiring change is required.
Q2: What commissioning steps are required after installing the DSSX110?
After installation, apply the specified mounting torque (1.5–2.0 N·m), restore power, and measure the DC bus output voltage under no-load conditions. Progressively restore load and verify bus voltage stability at each step. Use the drive’s built-in diagnostics or a calibrated clamp meter to confirm forward current is within the expected range. No PLC program modification is required.
Q3: Will the DSSX110 replacement affect my existing wiring or communication links?
No. The DSSX110 operates entirely within the power supply subsystem and has no connection to signal-level wiring, communication buses, or I/O circuits. PROFIBUS, PROFINET, EtherNet/IP, and Modbus links remain active and unaffected. HMI screens, SCADA data, and PLC program execution continue normally throughout the replacement process if auxiliary power is maintained.
Q4: What warranty coverage is provided, and has the unit been tested before shipment?
Every DSSX110 supplied by SMARTNEXMSK is covered by a 12-month warranty against manufacturing defects from the date of shipment. Each unit undergoes pre-shipment functional testing to verify forward voltage drop, reverse leakage current, and package integrity. Units are shipped in anti-static packaging with full traceability documentation available on request.
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