P 664
P 664
P 664
R. A. Winje, P. J. Reardon
National Accelerator Laboratory':'
E. R. Schoop, W. A. Manahan
Transrex Division, Gulton Industries, Inc.
In addition to stability, the fact that the When the proposals were analyzed, it
primary beam momentum will be varied irom became clear that for a production run of about
50 GeV to 500 GeV with multiple momentum 40 units, the cost for the 500 kW power supply
ranges of the secondary beams at each of the with different voltage settings compared
primary beam settings caused us to consider favorably with the cost of twenty 350 kW supplies
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and twenty 500 kW supplies. The Transrex Description
Division of Gulton Industries was awarded the
contract and proceeded to design a prototype The power supply is a 500 kW twelve
six phase 500 kW supply. The tap settings were phase unit with a unique arrangement of secon-
changed to 1000/0, 50%, and 25% to obtain a better dary connections, whereby the dc output of the
balance over the range of loads to be employed. power supply is able to provide a wide range of
voltages and currents. The output character-
Subsequent to the award, it was recog- istics of the power supply are shown in Table I.
nized at National Accelerator Laboratory that
in the future, when upwards of 100 of these Rather than using the conventional wind-
large power supplies were likely to be in service ing technique in the primary in which taps are
simultaneously, the power factor of the six added at discreet points along the winding, the
phase power supplies would in all likelihood be power supply has a quadrifilar wound primary.
low enough to require power factor correction. This allows the primary to be reconnected to
The problem was discussed with Transrex and change the basic power rating of the power
the system was changed to a 12 phase system supply. The electrical equivalent to 25%, 50%
after the completion of one supply with a six and 100% full current, non-load changing taps
phase system. Later on, as the requirements are available.
for the Proton Laboratory beam layouts became
clearer, there was pressure to change the The rectification of the ac power and the
earlier decision on limiting the types of supplies control of the resultant dc power is done by
in the experimental area and to allow two more phase control of thyristors in a 12 phase, half-
types to be purchased; one to be approximately wave double star connection located on the
a 2000 A, 150 V supply and the second to be a secondary side of the power transformers.
1200 A, 400 V supply. It was at this time that Full current rated free wheeling diodes across
we came up with the idea that whereby inter- the power supply output are included.
connecting the four 100 V, 1250 A half-wave
units, on our already existing 12 phase, 500 kW Stability of the output current is obtained
supply, we could make a series parallel by a self contained current and voltage regulator
connection to obtain 200 V, 2500 A, and in a shown in a simplified block diagram in Fig. 2.
total series connection, we could obtain 400 V The regulator is designed to be stable over a
and 1250 A. Since we planned to retain the load resistance range from two milliohms to
primary taps, we now would have what we were 1000 milliohms and time constants ranging from
looking for all along - - a very stable, program- 1/2 to 3 seconds. It was anticipated that the
mabIe power supply with flexible enough voltage output current would be stable to better than
and current arrangements to meet all of our 0.01% long term in the presence +5%, -7o/r line
experimental area requirements from 1000 A voltage changes and a 10% change in load
to 5000 A and 25 V to 400 V. The proposed resistance.
changes were discussed with Transrex and the
final detailed design of the new system was made The power supply is complete with its
by them. The development of this flexible power own interlock chain with protective devices
supply has been mutually accomplished by installed to detect abnormal conditions, which,
National Accelerator Laboratory and Transrex when activated will shut down the power supply.
and has worked out very satisfactorily in the
Proton Laboratory beam transport area and in Output
the Neutrino Laboratory. Additional supplies
have been installed in the Meson Laboratory and The basic power rating of the power
in the Proton Laboratory. They will all be in supply was determined by considering the types
service by the end of this year. We are now and distribution of the magnet loads. Cur rents
considering the addition of reversing switches approaching 5000 A for some of the bending
and filters; although, as far as the latter is magnets and quadrupole magnets used in the
concerned, our experience to date indicates experimental area of the Laboratory are
that external filtering will not be required in required during a 500 GeV operation. Likewise,
most cases. The cost of the power supply some magnets in the high impedance range were
described in this paper is approximately $35 also contemplated for use in the experimental
per kW. area. For' these magnets, currents approaching
1200 A are required for maximum excitation.
Typically up to five magnets can be series
connected to one power supply. In cases where
more than five magnets are required to be series
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TABLE 1. Output Characteristics
Maximum dc Maximum
Secondary Voltage Available Minimum & Maximum
Connections (100% Connection) Output Current Maximum Load':' Available Power
(volts) (amperes) (milliohms) Primary Connection
25% 50% 100%
(kilowatts)
Parallel 100 5000 2. 5 - 20 125 250 500
Series -
Parallel 200 2500 10 80 125 250 500
':'The minimum value of the range was determined by considering that the maximum output current
may be drawn to 50% of the rated output voltage on each primary connection.
connected, up to three power supplies can be amplifiers can be done without incurring large
added to achieve the higher voltage. In this phase shifts at the primary voltage frequency.
mode of operation only one supply is current Additional benefits arise because the overall
regulated while the others are voltage regulated. conversion efficiency is improved. In many
In those cases where two or more power supplies cases the higher conversion frequency has also
need to be parallel connected to increase the eliminated the need for filtering of the output
total available current, an external current of the power supply.
sensor and regulator amplifier would need to be
provided. Then, the power supplies would be Our choice was then the twelve phase
operated as voltage regulated units. The open (720 Hz) conversion frequency over the more
loop gain of the voltage amplifier is high enough conventional six phase (360 Hz). In some power
to insure stability and equal loading of the power supply designs. this decision could have resulted
supplies. in twice as many thyristors as the six phase
design; however, in our case the same number
The ratings of all the components of the resulted due to the basic 5000 A output current
power circuits meet the NEMA standards for requirement.
overload conditions; that is, 120% for two hours.
Also, the power supply may be pulsed to 7000 A Input Power
on a 50% duty cycle.
The input to the power supply is the
Conversion Frequency utility standard 460 V. 3 phase. 60 Hz power.
This is fed to the internal circuitry through a
The choice of the conversion frequency 1000 A molded case. air insulated circuit breaker
was made by considering the overall effects of with a 35,000 A interrupting capacity.
many of these power supplies operating simul-
taneously on our primary ac distribution system. Power Conversion
At the Laboratory, the primary power to the
equipment areas is fed by buried 13.8 kV. Circuit
3 phase feeders to strategically located. outdoor
type unit· substations of the 1500/1900 kVA. In the original stages of design it was
480 V. 3 phase class. Several power supplies tempting to consider obtaining the 720 Hz output
are connected to a single' unit substation. thus ripple by utilizing only one rectifier transformer
raising the possibility of power supply inter- with four zig-zag secondary Windings displaced
actions. or cross talk. The severity of this by 15 0 • Careful study of the mechanical inter-
problem can be reduced. although probably not connections required showed that it would be
eliminated. by operating at a high conversion more economical to utilize two transformers
frequency. This improvement occurs because with identical secondaries but with their
the input line currents contain less harmonic primaries shifted by 30 0 • Therefore. the
currents at the higher conversion frequencies. primaries were designed to be delta in one
Therefore. selective filtering of the ac transformer and wye in the other. In addition
synchronizing voltages for the thyristors gating to the 720 Hz output ripple. it had been decided
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to provide four separate and distinct 100 V Firing circuits located in the electronics
sections l each one with a capability of 1250 A. assembly transmit the 24 V peak triggering
It became evident that the best rectifier circuit pulses on coaxial cable to the gate firing circuits.
to obtain these outputs was a six phase star with The firing circuits employ a linear ramp which
interphase transformers (Fig. 3). One half of is compared to the control input signal to trigger
each secondary would then provide the required a monostable multivibrator to produce the firing
100 V at 1250 A. pulse. The ramp is gated on-and-off by a phase
related 50 V ac line signaL The high amplitude
The four separated 100 V power sections of this line signal, plus some filtering ensures
l
are then added in a series connection l keeping a noise free 180 degree ramp. The ramp has
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the two interphase transformers in the circuit l a peak amplitude of 10 to 12 V so the input
to achieve 400 V at 1250 A. Paralleling the two control signal range must be zero to 11 V.
secondary halves of each power transformer This high amplitude improves tolerance to
and adding them in series gives an output of signal harmonics as well as noise.
200 V at 2500 A. Likewise paralleling both
power transformer sections through the third Free Wheeling Diodes
interphase transformer gives an output of 100 V
at 5000 A. The freewheeling diodes were originally
selected to carry 5000 A continuous dc with a
The primary winding of the two power 25% temperature safety margin. This reqUired
transformers are wound as four separate, but using three PSI-HD2500 diodes in parallel.
paralle1 1 windings. Thus l through a convenient- The reconnectable secondary configuration used
ly located tap board the four primary windings
l
one freewheeling diode in each of the four half-
can be connected either in series l series- wave star sections so the diode might have been
parallel l or all in parallel to obtain the 250/0, changed to a HD2000 but use of the HD2500
1
50%1 and the 100% connections. This provides continued in the production run. This provides
the flexibility to properly match the power a derated continuous current capability of
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constant at any tap. Another advantage is that voltage which supplies ac power to the power
because the winding is symmetrical, all the supply also is characterized by both fast and
windings carry the same current for a given long term changes. At the Laboratory, 5%
load current regardless of the tap. Still another changes are not uncommon. The line voltage
advantage, tap changing is done in the primary can be seen to dip by about O. 5% just due to the
where currents are lower and no overwinding is operation of the accelerator alone.
necessary. The only major disadvantage of
this arrangement is caused by the fact that under Although most of the copper conductors
certain connections the voltage gradient between in the magnets are water cooled, they still
turns can be very high and thus extreme care exhibit a change in resistance due to the change
is required in the design and construction of the in temperature. This change can be as much
primary windings. as 10 to 15%.
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necessary to adjust the frequency response of This assures a first order, stable system
the current regulator to match the various throughout the system bandwidth. The loop
magnet resistances and time constants to achieve gain, which always exceeds 10, 000 (80 dB),
the desired response. provides a gain bandwidth of 5 Hz.
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TABLE III. Transductor Characteristics be performed. These functions include ON-OFF
control and monitoring, fault monitoring and
reset, and output current and voltage control and
Sensitivity 500 A/V monitoring.
Coefficients
line voltage 5 ppm/% change The power supply output is controlled by
tempe rature 1 ppm/oC means of a reference voltage which is applied to
Frequency Response 1000 Hz the input of either the current loop or voltage
(N ominal, - 3 dB) loop amplifier. The output of the internal
precision reference voltage supply is applied
to the power supply input by means of a
Control System potentiometer driven by a pulse controlled
stepping motor. The stepping motor and the
Power Control multi -turn potentiometer were chosen to provide
a resolution of at least 100 ppm. Application
The power supply contactor is energized of 5 V, 50 microsecond pulses to the cw
by means of a relay-based interlock and control (increase) or ccw (decrease) inputs of the motor
system. All fault signals are connected into logic are reqUired for operation of the motor
the control chain through auxilliary contacts of driven potentiometer.
the sealed-in relays of the protective devices.
The power supply may also be pro-
The ON-OFF control and the reset grammed either by means of a remotely located
functions can either be operated locally or waveform generator or an optional ramp and
through a set of remotely located relay contacts. flat -top generator which may be added to the
Local monitoring of the status of the interlock power supply. In either case, the rate of
chain and fault indicators is provided. change in the output is generally dependent
upon the time constant of the load and the
Protection available output voltage; and to a lesser degree,
the speed of response of the power supply.
The power supply is completely self
protected against ac overloads and current Mechanical
unbalance, dc overloads and over temperature.
The power thyristors and free wheeling diodes The components of the power supply are
are protected against over temperature by housed in a steel frame, free-standing structure
means of bi -metallic thermostats placed on designed for indoor use. Steel panels with front
each device. In addition each power thyristor door accessibility cover the unit giving drip
is protected by a Carbone-Ferraz 1250 A fuse. proof construction (Fig. 6). The dimensions of
The operation of any of the protective devices the power supply are 122 em x 122 cm x 183 em
will cause the interruption of the gate pulses high (48 in. x 48 in. x 72 in. high) and the
to the thyristor as well as the opening of the weight is 2700 kg (5900 lb). All power connec-
primary ac contactor. Provisions are also tions (ac and de) are made at the top. Water
included for remote load fault sensing. supply and return connections are also made
at the top.
Ground faults are detected by means of
a current sensitive trigger fuse. Upon acti- All the electronics for the power supply,
vat ion, the firing circuit input is shorted and with the exception of the transductor electronics,
the primary contactor is de-energized. The are mounted in a NIMBIN assembly which is
load is protected from. excessive instantaneous located on the front of the power supply.
currents by a 200 ohm. current limiting resistor. (NIM: AEC Standard TID-20893, Nuclear
Instrumentation Module) The heavy duty
The control of the protective devices are components such as the main circuit breaker
included in sealed -in fault indication and control and contactor are mounted on an insulated
relays. The operation of the protective device panel board located about 36 em (14 in) behind
will remain indicated until the operator, through the front door.
the control system, resets the power supply.
The two main power transformers are
Computer Control located in the lower half of the power supply.
Primary connection changing is done from the
In addition to the local control a limited front. Each power transformer assembly also
number of remotely controlled operations can contains its own double wye interphase trans-
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former. The combining interphase transformer operating on the 1000/0 primary connection. The
for the delta -wye unit is located on the left side load was a 95 milliohm water cooled resistor.
of the power supply, immediately behind the The results of this analysis, presented in
panel board. Table IV, demonstrate the benefit of operating
at the higher conversion frequency. The total
The secondary series-parallel connec- harmonic content was about 4. 4%. It would be
tions are made with water cooled links. The expected that with an inductive load the harmonic
links are accessible through the side panels. currents would be smaller.
About 8 links are required to be moved in
changing from one connection to another. Expe- TABLE IV
rienced technicians can change the connections Harmonic Analysis of the Input Line Current
in about one hour.
Harmonic Frequency Harmonic Current
The thyristors and free wheeling diodes Number Hz (% of fundamental)
are located at the rear of the power supply
(Fig. 7). There are four separate assemblies, 1 60 100.0
one for each half-wave star section. Each 11 660 3.7
assembly is complete with its own free wheeling 13 780 1.5
diode. The bus-bar from the power transformer 23 1380 1.0
secondary is connected to the thyristor heat 25 1500 0.5
sink through the current limiting fuse. 35 2100 0.5
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voltage of 79 V. The maximum resistive Acknowledgements
component voltage was 34 V. Because the
power supply was voltage limited to 100 V the The authors wish to express their
current pulse becomes rounded after O. 3 sec. appreciation to Mr. Jan Ryk, National
Within the limits of the bandwidth of the current Accelerator Laboratory, for providing the
regulator and the available output voltage, the stability and ripple current data and to
output current settled to the basic steady-state Mr. Eugene Woods for providing assistance
stability, characteristic of the power supply in in obtaining the pUlsed operation data.
about one second.
.
CHICAGO CYCLOTRON
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_---------
---------\-----
MU\ON BEAM
/
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LAB 'c'
(E\ IA)
NEUTRINO BEAM
;. 1
WONDER
BLDG.
(E·21) V B~BLE
HADRON BEAMS
30"
CHAMBER
0=
NEUTRINO LABORATORY
1--1000' -----t
SCALE
Fig. 1. Neutrino beam line. Many of the power supplies described are in the service buildings and
equipment enclosures located along these beam lines. Similar conditions exist for the
Meson beam line (to the left of the Neutrino beam line) and for the Proton beam line (to the
right of the Neutrino beam line).
4S0V
af
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Fig. 4. Regulator System block diagram.
Fig. 6. Power Supply - Front View, external Fig. 7. Power Supply - Rear View, internal
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