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New active filter for COSY dipole power converter

New active filter for COSY dipole power converter. May 29, 2016 | Markus Retzlaff & Christian Ehrlich Many thanks for the support of the IKP-4 Members, FZJ BoD and the HGF Members. Summery. Power converter overview Interaction between thyristor- & parallel feeding - stage

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New active filter for COSY dipole power converter

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  1. New activefilterfor COSY dipole power converter May 29, 2016 | Markus Retzlaff & Christian Ehrlich Manythanksforthesupportofthe IKP-4 Members, FZJ BoDandthe HGF Members

  2. Summery Power converteroverview Interaction between thyristor- & parallel feeding- stage Development stepsforthenew parallel feeding, by Markus Retzlaff & Christian Ehrlich Development ofthenewtransistordriver, by Christian Ehrlich Development ofthenewlinear stage, byMarkus Retzlaff

  3. Power converteroverview controlcabinetthyristorcabinet parallel feeding 2600 x 2200 x 850 mm 5200 x 2200 x 1200 mm 3000 x 2200 x 900 mm

  4. Power converteroverview outputcurrent5000 A (20ppm), outputvoltage1250 V, 6.25 MW Thyrister stage Parallel feeding COSY dipolemagnets 24 (25)

  5. Power converteroverview Interaction between thyristor- & parallel feeding- stage Development stepsforthenew parallel feeding, by Markus Retzlaff & Christian Ehrlich Development ofthenewtransistordriver, by Christian Ehrlich Development ofthenew linear stage, by Markus Retzlaff

  6. Interaction between thyristor- & parallel feeding- stage Main Current IM = IS + IP Thyristor Current IS PrallelfeedingCurrent IP

  7. Power converteroverview Interaction between thyristor- & parallel feeding- stage Development stepsforthenew parallel feeding, by Markus Retzlaff & Christian Ehrlich Development ofthenewtransistordriver, by Christian Ehrlich Development ofthenew linear stage, by Markus Retzlaff

  8. Development stepsforthenew parallel feeding by Christian Ehrlich Extension forthenew linear stage New transistorgatedriver New activefilterstructure New linear stage by Markus Retzlaff

  9. Power converteroverview Interaction between thyristor- & parallel feeding- stage Development stepsforthenew parallel feeding, by Markus Retzlaff & Christian Ehrlich Development ofthenewtransistordriver, by Christian Ehrlich Development ofthenew linear stage, by Markus Retzlaff

  10. The oldtransistordriverfrom 1988 Fourversions: 029.105.454 (switchstage „oben“), 029.105.546 (switchstage „unten“), 029.105.458 (analog stage „oben“), 029.105.460 (analog stage „unten“)

  11. The newtransistordriver One Mainboard for all versions. Setting withselectorswitch

  12. PCB settingidicator Global pcbsettingindicator & switch PCB settingswitch (one Mainboard for all fouroldversions)

  13. Single pcbsettingidicator, „OK“

  14. Single pcbsettingidicator, „wrong“

  15. Major functions The newtransistordriver must havethe same sevenmajorfunctions: Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor monitoring Resetdriver Transistor gatedriver (BUZ45) Logicforinterlocks

  16. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  17. Voltagemonitor Status display Measuringpoints

  18. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  19. Gridsynchronisation 20ms warning 10ms 10ms normal operation

  20. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  21. 10ms = normal operation Fiber opticcommunication LWL 20ms = warning Testpoints > 20ms = shutdown

  22. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  23. Version „unten“ (down) Input portsandMiniSemimonitoring MiniSemiforthe intermediate circuit

  24. Version „oben“ (up) Output ports warning shutdown LWL wire Transistor gatedriver „unten“ Transistor gatedriver „oben“ Warningoutput Shutdownoutput

  25. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  26. Transistor gatedriver Gate connectionto 384 BUZ45 transistors

  27. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  28. Oneofthetransistorholders 384 BUZ45 Transistors 128 transistorgroups (6 in eachgroup) Transistor monitoring shutdown= 3groupsfailure warning= 1 groupfailure 1750 mm 1100 mm

  29. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  30. Resetdriver Single transistorgroupmonitoring errormemory

  31. Module functions Voltagemonitoring Gridsynchronisation Fiber opticcommunication IO-Ports Transistor gatedriver (BUZ45) Transistor monitoring Resetdriver Logicforinterlocks

  32. Logicforinterlocks, „oben“ & „unten“ • Every signal on testpoints • Nosoftwareused, onlygatterlogic

  33. Logicforinterlocks, version „unten“ • Every signal on testpoints • Error memory • with LED • Nosoftwareused, onlygatterlogic

  34. Logicforinterlocks, version „oben“ • Every signal on testpoints • Error memory • with LED • Nosoftwareused, onlygatterlogic

  35. Old mainboard had to be calibrated after repair, in case of an error

  36. The new mainboard is balanced in itself, by calibration of the function modules

  37. Resistorsforcalibration Every spare parts are calibrated with the external testing bench

  38. Repair without special knowledge about the dipol power converter is possible defectpcb out testedpcb in

  39. Maintenance time is much shorter • All terminalsofthemainboardarepluggable • All functionblocksare modular • All spare partsarecalibrated • Onemainboardfor all fouroldversions • „siri-function“ for PCB settingcontrol • All importantsignalsarefeddirectlyto LEMO socketsortestpoints • Compatiblewitholdupperboards E1-E3 • Nospecialknowledgeoftheactivfilterrequired, all componentsarecodedandclearlylabeled

  40. Necessary modifications and difficulties in developing • Currentconnection must bechangedto terminal blocks • Nofurthermechanicalworknecessary, becausetheentiremechanismand terminal positioningisequaltotheoldversion • Difficultiesduringplanninganddevelopment: • Measuringofthedipolelectronicsonlyduringmaintenancepossible • Incompletedocumentation • Subtledifferences in theoldversion • Handmadeconnections on theoldpcb

  41. Power converteroverview Interaction between thyristor- & parallel feeding- stage Development stepsforthenew parallel feeding, by Markus Retzlaff & Christian Ehrlich Development ofthenewtransistordriver, by Christian Ehrlich Development ofthenew linear stage, by Markus Retzlaff

  42. Same connectionfromthemainboardtotheinterface Interface for the new linear stage

  43. Same Reset- andTransistormonitoringsignals Interface for the new linear stage

  44. The old linear stage • MOSFETS areconnected in parallel, withdrainresistors. • Nocontrolledsymmetry, so wehavetorely on thesymmeteryofthetransistorsthemselfs • Groups ofsixtransistorsaresupervized, todetectdriftsorbrokenones • Modern versionsofthe MOSFETs (BUZ45A) haveenormousdrifts, so wecannotusethem in parallel connection. Orwehavetoselectthemwithgreatdiscard.

  45. The new linear stage • Each MOSFET has ist ownregulation, forbettersymmetry • Each MOSFET has ist ownfailuredetection • MOSFET from IXYS speciallydesignedfor linear regulation • SOT-227 caseinsteadof TO-3

  46. The new linear stage • Easy daisychainconnectionoftheregulationboardswith FFC andbusbars

  47. Outlook for the linear stage • In thefuture, the intermediate circuit will bedynamic, insteadofthestaticsystemfromnow. This woulddramaticallyreducethe power lossofthe linear stage, andwecan also reducethenumberoftransistors. • This will berealizedwith a source- / sink power converter, tobeable, tofeedtheenergy back intothemains, duringdischargingthemagnets.

  48. Thanksforyourattention

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