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
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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