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Specification for the Driver Coil Modules Capacitor

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Specification for the Driver Coil Modules Capacitor Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 Specification for the Driver Coil Modules Capacitor Charge/Discharge Power Supply (CCDPS) for FLARE March 10, 2016 1 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 Contents 1 Specifications for Driver Coil (DC-I and -O) bank modules 4 1.1 Description . 4 1.2 Full Assembly . 7 1.2.1 DC-I module . 7 1.2.2 Full Assembly: DC-O module . 8 1.3 Capacitors . 9 1.4 Forward Switch . 9 1.5 Crowbar Diodes . 10 1.6 Buswork . 10 1.7 Charging . 10 1.8 Dump . 11 1.9 Harnessing . 12 1.10 Polarity switching . 12 1.11 Diagnostics . 12 1.12 Safety . 12 1.13 Cooling requirements . 12 1.14 Connection schematic . 12 1.15 Environmental requirements . 13 2 References 14 3 Appendices 14 3.1 Machining drawings and vendor specifications . 14 2 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 List of Tables 1 Target parameters for DC bank . 4 List of Figures 1 Driver Coil Circuit Schematic . 4 2 PSpice DCI Schematic and Analysis . 5 3 PSpice DCO Schematic and Analysis . 6 4 Engineering design point for bank module . 7 5 Engineering design point for bank module . 8 6 Detail of the cap headers for the DCI (left) and DCO (right) bank modules. 9 7 Detail of the switch for the DCI and DCO banks (they are identical). 10 8 Charge dump relay . 10 9 Dump detail for the DC bank module. 11 10 Connections . 13 11 Schematic for charge, dump and ground relay control. 14 12 DCI Capacitor Header Adapter for Nipple . 15 13 DCO Capacitor Header Adapter for Nipple . 16 14 Aluminum Nipple . 17 15 Diode Clamp Upper/Lower . 18 16 Nipple Cap . 19 3 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 1 Specifications for Driver Coil (DC-I and -O) bank modules 1.1 Description Bank schematic is shown in Fig. 1 for each of the two DC bank modules. Starting on the left side of the figure, the module is charged by connecting both positive and negative supply lines. A power supply protection circuit is shown (please refer to the Charge Specification for details). A bleed resistor is connected in parallel with the capacitor and is used to slowly drain bank charge in case of failure of all other dumps (i.e. if left alone overnight the bank will passively discharge below the NFPA 70E safe approach threshold of 50 V). Before each shot, the dump load relays are opened. Then the charging relays are closed and the charging supply charges the caps. When the set-point is reached, the charging switches are opened. The capacitors are then discharged through the inductive and resistive load of the coil, and crowbarred with a delay corresponding to peak current. For DC-I and DC-O, the first swing current will always be greater than zero, and a switch is used to crowbar the circuit. Following a shot, the dump switch is closed to ensure the capacitors are fully discharged. Each of the components will be described in the following sections. Figure 1: Driver Coil Circuit Schematic The DC bank modules are designed to energize the inboard and outboard Driver Coil set, providing a current pulse per Fig. 2 and Fig. 3, meeting the specifications in Table 1. The power supply system shall be designed for a minimum of 10 years design life and a minimum of 100,000 full power shots with regular maintenance. DC-I DC-O # Sub-Coils 2 2 V (Volts) 60000 60000 Imax (A) 50000 50000 Day 1 0 0 Peak I (kA) 50 50 trise (ms) < 0.01 < 0.03 tcrowbar Peak Peak Swing Imin +ve +ve Table 1: Target parameters for DC bank 4 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 V3 TD = 1n 0 TF = 1n PW = 1 0 PER = 2 + - V1 = 0 R19 S3 + - TR = 1n C13 1m S R10 L6 V2 = 5 10n VON = 1.0V R4 1.45e-2 1.97e-6 I .01m VOFF = 0.0V K K12 K_Linear 0 COUPLING = .755 L7 R20 3.7e-7 .003 S4 V4 - - C4 L4 L3 I I + 0 + 1.51e-9 1.45e-6 1.45e-6 IC + 30k TD = 4.8u0 C15 C14 S TF = 1n C3 VON = 1 PW = 1 3.2e-8 3.2e-8 .0026m VOFF = 0 R2 R7 + R5 0 IC PER = 2 .000325 .000325 -30k V1 = 0 0 R18 TR = 1n .1e-4 100meg V2 = 5 0 ** Profile: "SCHEMATIC1-trans" [ C:\Users\simon\Dropbox\PPPL-FLARE\cdr\Full Power\Bank8 Inside Driver C... Date/Time run: 02/25/16 15:08:38 Temperature: 27.0 (AN) trans.dat 60KA 50KA 40KA 30KA 20KA 10KA 0A 0s 20us 40us 60us 80us 100us I(L6) I(L3) I(L4) Time Date: February 25, 2016 Page 1 Time: 15:13:02 Figure 2: PSpice DCI Schematic and Analysis 5 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 V1 TD = 1n 0 TF = 1n PW = 1 0 PER = 2 + - V1 = 0 L3 S1 + R19 - TR = 1n C13 S R3 V2 = 5 10n VON = 1.0V 8.22e-3 R6 1.97e-6 C2 1m I .01m VOFF = 0.0V 1.51e-9 0 K K12 L4 K_Linear V2 3.7e-7 COUPLING = .819 R4 S25m L2 L1 TD = 13u I - - 0 TF = 1n 7.88e-6 7.88e-6 + + 0 IC + 30k PW = 1 C14 PER = 2 S V1 = 0 10n C1 VON = 1 R2 R1 + TR = 100n IC 0.00675m VOFF = 0 R5 .0013 .0013 -30k V2 = 5 0 2e-3 R18 100meg 0 ** Profile: "SCHEMATIC1-trans" [ C:\Users\simon\Dropbox\PPPL-FLARE\cdr\Full Power\Bank9 Outside Driver ... Date/Time run: 02/25/16 15:10:15 Temperature: 27.0 (AO) trans.dat (active) 60KA 50KA 40KA 30KA 20KA 10KA 0A 0s 50us 100us 150us 200us I(L3) I(L1) Time Date: February 25, 2016 Page 1 Time: 15:14:28 Figure 3: PSpice DCO Schematic and Analysis 6 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 1.2 Full Assembly 1.2.1 DC-I module Revisions Zone Rev Description Date Approved Unless Otherwise Specified: Name Date Dimensions in Inches Drawn Woodruff Scientific Tolerances: Fractional ± Angular: Mach ± Bend ± Checked Two Place Decimal ± ENG Appr. Three Place Decimal ± DCI MFR Appr. full system view QA Comments Material Size Drawing No. Rev -- CAD Generated Drawing Do Not Manually Update Finish A 0001 A -- Do Not Scale Drawing Scale 1:1CAD File Sheet 1 of 1 Figure 4: Engineering design point for bank module Fig. 4 shows the full bank assembly mounted on one 36 inch square steel pallet. The full assembly will have a footprint smaller than 16sqft with a maximum of 64sqft for egress and maintenance (2 feet on each side), and will be engineered as 1 module that can be transported and installed onsite with only a small number of connections (connections for 110V power, hight voltage and trigger lines (see more details below and connection table below)). The DC Bank and all related components will be mounted on 2 36"x36" standard pallets, total height under 50 inches, total weight per pallet of 1200lbs. Assembly instructions will be provided separately. 7 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 1.2.2 Full Assembly: DC-O module Revisions Zone Rev Description Date Approved Unless Otherwise Specified: Name Date Dimensions in Inches Drawn Woodruff Scientific Tolerances: Fractional ± Angular: Mach ± Bend ± Checked Two Place Decimal ± ENG Appr. Three Place Decimal ± DCO MFR Appr. Full system view QA Comments Material Size Drawing No. Rev -- CAD Generated Drawing Do Not Manually Update Finish A 0001 A -- Do Not Scale Drawing Scale 1:1CAD File Sheet 1 of 1 Figure 5: Engineering design point for bank module Fig. 5 shows the full bank assembly mounted on one 36 inch square steel pallet. The full assembly will have a footprint smaller than 16sqft with a maximum of 64sqft for egress and maintenance (2 feet on each side), and will be engineered as 1 module that can be transported and installed on-site with only a small number of connections (connections for 110V power, height voltage and trigger lines (see more details below and connection table below)). The full DC Bank (DC-I and DC-O) and all related components will be mounted on 2 36"x36" standard pallets, total height under 50 inches, total weight per pallet of 1200lbs. Assembly instructions will be provided separately. 8 Woodruff Scientific Inc. Specification for DC Bank Modules March 10, 2016 1.3 Capacitors Figure 6: Detail of the cap headers for the DCI (left) and DCO (right) bank modules. The DC Bank will use 2 60kV Capacitors, with 2.5uF on the DC-I and 7.5uF on the DC-O, by Richardson Electronics. The capacitors are expected to see reversal voltages during the experimental shots. Capacitor casing will be hot, and in bipolar charging operation, will see -30kV. Cap casing is therefore isolated from the pallet (at ground) by multiple layers of mylar, and a 3” thick high density extruded polystyrene sheet (to ensure stand-off and even-distribution of weight on the mylar). The caps are rated for 80% discharge voltage reversal. The capacitors are expected to survive at least 500,000 full power shots without failure, per cap manufacturer specification see appendix for the Richardson specification. Each capacitor unit is self- protected with a resistive load between cap and switch consisting of 8 stainless resistive shunts connecting the anode of the capacitor to the anode of the switch.
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