30kA Energy Extraction Semi-Conductor Switch PRR: 29-02-2016 SM18 - CLUSTER D Dump Resistor Prototype 15 kA/5 MJ Slide 1/12 Szymon Michniuk, 29.02.2016 Dump Resistor Prototype 15 kA/6 MJ Energy Extraction System Overview: 1. 2. 3. 4. 5. 6. 7. 8. Overview of the EE system and rated parameters of the dump resistor Design details of the dump resistor Modularity Resistance measurement studies – safety purposes Parasitic inductance measurement results Energy deposition abilities of the dump resistor Thermal results Improvements and future design details for the final product Slide 2/12 Szymon Michniuk, 29.02.2016 Place of the dump resistor in the 15/30 kA system Slide 3/12 Szymon Michniuk, 29.02.2016 Requirements and ralated parameters of the dump resistor Parameter Value Amount of energy which can be dissipated Emax 6 MJ Withstand voltage Umax (in respect to the ground) 2.5 kV Insulation resistance under maximum voltage Riso ≥100 GΩ Number of independent resistor modules Resistance of single module 6 Maximum cooling time 45 min Maximum continuous operating temperature 150 °C ΔT (1 MJ operation per resistor module) ≤70 °C Cooling principle Temperature coefficient (calculated theoretically) Thermal bi-metallic switch threshold *to be adapted to safe operation Slide 4/12 42U 40 mΩ ± 10 % natural convection -0.33 %/°C 70 °C (*) Szymon Michniuk, 29.02.2016 Dump Resistor for the 15/30 kA Energy Extraction System Mechanical details flexible connections 2x200 mm2 short copper busbars long copper busbar Slide 5/12 Szymon Michniuk, 29.02.2016 Examples of possible configurations R [mΩ] Emax [MJ] Umax=1 kV Imax [kA] 6.67 6.00 149.93 8.00 5.00 125.00 26.67 6.00 37.50 60.00 6.00 16.67 90.00 2.25 11.11 180.00 4.50 5.56 200.00 5.00 5.00 240.00 6.00 4.17 25 possible configurations Slide 6/12 Szymon Michniuk, 29.02.2016 Resistance measurement study – mistakes prevention Power Converter and IGBT Switch interlocks external devices (f.e. display) Slide 7/12 Szymon Michniuk, 29.02.2016 Parasitic inductance measurement Case Modules connected in series Modules connected in series + cable Cable Modules connected in parallel Modules connected in parallel + cable 5.5 technical method Agilent 4263B LCR Resistance Inductance [mΩ] [uH] 233.2 1.99 238.52 3.78 4.78 2.18 11.56 0.73 - Technical method Resistance Inductance [mΩ] [uH] 232.4 2.02 235.8 3.61 12.4 1.92 7.6 0.45 16.2 2.1 Resistors connected in series + cable 5 Inductance [uH] 4.5 4 3.5 3 2.5 2 Agilent 4263B LCR Meter Slide 8/12 1.5 0 10 1 10 2 10 3 10 Frequency [Hz] 4 10 5 10 6 10 Szymon Michniuk, 29.02.2016 Prototype test - maximum energy deposition Dump resistor test configuration Maximum values during the tests: The voltage across the dump resistor: 160 V The dump resistor current: 3 kA Slide 9/12 Szymon Michniuk, 29.02.2016 Thermal behaviour thermostats threshold = 70°C ceramic maxiumum operating carbon temperature 150 °C discs Pt100 R6 R5 R4 R3 R2 R1 Slide 10/12 Szymon Michniuk, 29.02.2016 Possible configurations of the final product Additional connection flags at the back of the modules Slide 11/12 Szymon Michniuk, 29.02.2016 Summary and future improvements Summary: - the dump resistor is able to dissipate 6 MJ - the parasitic inductance (the worst case) is lower then 5 uH - the modularity of the dump resistor is provided Future improvements: - thermal time constant will be improved by optimizing mechanical layout of the rack - optimalization of location of the thermal probes to be done - the maximum dimensions of the rack – to be determined as soon as possible Slide 12/12 Szymon Michniuk, 29.02.2016