System Design and Measurements of a 115-kV/3.5-ms Solid-State Long-Pulse Modulator for the European Spallation Source

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1 System Design and Measurements of a 115-kV/3.5-ms Solid-State Long-Pulse Modulator for the European Spallation Source M. Jaritz, J. Biela Power Electronic Systems Laboratory, ETH Zürich Physikstrasse 3, 8092 Zürich, Switzerland This material is posted here with permission of the IEEE. Such permission of the IEEE does not in any way imply IEEE endorsement of any of ETH Zürich s products or services. Internal or personal use of this material is permitted. However, permission to reprint/republish this material for advertising or promotional purposes or for creating new collective works for resale or redistribution must be obtained from the IEEE by writing to pubs-permission@ieee.org. By choosing to view this document you agree to all provisions of the copyright laws protecting it.

2 3232 IEEE TRANSACTIONS ON PLASMA SCIENCE, VOL. 46, NO. 10, OCTOBER 2018 System Design and Measurements of a 115-kV/3.5-ms Solid-State Long-Pulse Modulator for the European Spallation Source Michael Jaritz, Member, IEEE, and Juergen Biela, Senior Member, IEEE Abstract In this paper, the results of a 2.88-MW solid-state long-pulse modulator, which has been designed for the new linear collider at the european spallation source in Lund, are summarized. The presented modulator generates an output voltage pulse of 115 kv with a pulselength of 3.5 ms. The main components of the modular system, which include a series parallel resonance converter, a high-voltage high-frequency transformer, and an output rectifier, are discussed. The modulator design is verified by measurements performed with a full-scale prototype, which is operated under nominal load conditions. A detailed output voltage ripple evaluation is given, and in addition, the system design has been proven by a 7- and 2/3-h heat run test. All specifications are well within the given limits, and the maximum occurring temperatures in the transformer stay below 110 C even under worst case assumptions. The system achieves a pulse efficiency (determined by the pulse shape) of 96.78%, an overall electrical system efficiency of 91.9%, and a combined pulse system efficiency of 89%. Index Terms Modular converter design, pulse power, series parallel resonance converter (SPRC). TABLE I MODULATOR SPECIFICATIONS I. INTRODUCTION FOR performing the planned high sophisticated material science experiments at the new linear collider at the European Spallation Source in Lund, Sweden, 2.88-MW longpulse modulators with a pulsed output voltage of 115 kv and pulse lengths in the range of milliseconds are required (see Table I). Applying direct switched topologies, as e.g., the approaches presented in [1] and [2], for these modulators have the drawback that the pulse generating components (e.g., solid state switch) have to be designed for the full pulse voltage, and this drawback could be avoided using pulse transformers. However, pulse transformer-based topologies (e.g., [3], [4]) require a huge transformer due to the high voltage time product caused by the large pulselength. In order to avoid the large transformers, series/parallel connected dc dc converters switching at a high frequency resulting in a small voltage time product for the transformer can be used. Such dc dc modules can be for example based on a single active bridge Manuscript received August 9, 2017; accepted February 8, Date of publication March 6, 2018; date of current version October 9, This work was supported by the project partners CTI and AMPEGON AG through the CTI-Research Project under Grant PFFLR-IW. The review of this paper was arranged by Senior Editor W. Jiang. (Corresponding author: Michael Jaritz.) The authors are with ETH Zurich, 8092 Zürich, Switzerland ( mi.jaritz@gmail.com; jbiela@ethz.ch). Color versions of one or more of the figures in this paper are available online at Digital Object Identifier /TPS converters with transformer and output rectifier as presented in [5], or on soft switched series parallel resonance converters (SPRC) as shown in Fig. 1(b) and presented in [6] and [7]. For generating the high output voltage, usually several modules are connected in series at the output. Due to the resonant tank, the SPRC has sinusoidal currents and voltages resulting in low electromagnetic interference and allows zero voltage switching for all switches, which is beneficial for MOSFETs and enables high switching frequencies. Therefore, that topology is chosen for the considered modulator system. The SPRC topology consists of 18 SPRC-basic modules (SPRC-Bm) [see Fig. 1(b)], which are operated at high switching frequencies ( khz) to minimize the dimensions of the reactive components and the transformers. Furthermore, to achieve the given pulse specifications in Table I, an optimization procedure is used to design the components. In this paper, a full-scale prototype system and measurements of the output voltage pulse for the prototype system are presented. In Section II, first, the optimization procedure required for determining the optimal design parameters is presented and all design results are summarized. Second, IEEE. Personal use is permitted, but republication/redistribution requires IEEE permission. See for more information.

3 JARITZ AND BIELA: SYSTEM DESIGN AND MEASUREMENTS OF A 115-kV/3.5-ms SOLID-STATE LONG-PULSE MODULATOR ESS 3233 Fig. 1. (a) Prototype system of the long-pulse modulator (specifications see Table I). The depicted setup includes two separate full-modulator systems (2 18 SPRC-Bms in total) with a power of MW during the pulse. (b) Block diagram of one full-modulator system, where two SPRC-Bms form an ISOP connected stack and 9 of the ISOP stacks are connected in parallel at the input and in series at the output forming an IPOS system [8], [9]. To balance the input voltages, active balancing circuits (i) are used. The modulator system is powered by the IVCU, which is a PFC boost converter. The full-modulator system has been built by AMPEGON AG. the built prototype system is introduced in Section III and the components of a SPRC-Bm are described. In Section IV, the critical temperatures of the transformers are determined under the assumption of a worst-case isolation oil temperature. Finally, the performance is evaluated by measured nominal output voltage pulses in Section V. II. OPTIMIZATION PROCEDURE Due to the high number of degrees of freedom as for example the transformer geometry, number of turns or the number of parallel semiconductor devices/chip area, and an optimization procedure, as depicted in Fig. 2, has been developed for optimally designing the modulator system. First, all electrical parameters as for example the primary current I prim of the transformer, the transformer turns ratio N, the switching frequency f, and the dc-link voltage V DL or the output voltage of the transformer V sec are determined with the electrical model of a single SPRC-Bm. These parameters in combination with the user-defined constraints are used within the optimization loops to minimize the transformer volume and to optimize the number of parallel switches of the full bridge for minimal losses. In addition, the transformer leakage inductance L σ and the stray capacitance C d are determined with models given in [7], because L σ is a part of the resonant inductance L S and C d is a part of the parallel capacitance C P. After the transformer optimization, a post isolation field conform design check of the transformer is performed with the help of FEM computations. This step is performed outside of the optimization loop, because it is not possible to include a detailed model of the complex isolation structure in the optimization routine without increasing the computational effort too much. The detailed description of the transformer optimization procedure is given in [10], and the applied thermal model of the semiconductor switches is presented in [6]. Fig. 2. Developed optimization procedure of the full-modulator system, which leads to an optimal design of a single SPRC-Bm and an optimal number of modules. Finally, if all global specifications (see Table I) are fulfilled, the procedure results in an optimal set of parameters and

4 3234 IEEE TRANSACTIONS ON PLASMA SCIENCE, VOL. 46, NO. 10, OCTOBER 2018 standard three phase 400-V grid and provides the 800-V dclink voltage V in for the SPRC-Bms. The voltage sharing between the SPRC-Bms could be balanced by the control presented in [8] and [9]. The controller also performs a droop compensation for a constant pulse voltage, which compensates the input voltage droop due to the high power consumption during the pulse. Furthermore details of the different control systems can be found in [8] and [9]. In the following, the optimized components of a single SPRC-Bm are discussed. Fig. 3. (a) Active input voltage balancing circuit operated with fixed switching frequency f bal and fixed duty cycle D bal in DCM. (b) Built balancing bridge. components of the SPRC-Bm and in an optimal number of modules for the modulator system. The optimization results for the considered specifications in Table I are summarized in Table II. III. PROTOTYPE SYSTEM Based on the optimization results, the prototype modulator system has been built and is presented together with the components of the single SPRC-Bm in the following. A. Full-Modulator System The diagram are depicted in Fig. 1(a) and (b). A single SPRC-Bm of the modulator consists of an MOSFET full bridge, a resonant tank, a transformer, and an output rectifier as presented in [11] and depicted in Fig. 1(b). Two SPRC- Bms with a 400-V dc-link voltage are connected in series at the input, sharing the same 800-V input voltage bus. At the output, the modules are connected in parallel, forming an input series output parallel stack (ISOP). To achieve the full output voltage and to deliver the full output power given in Table I, nine of the ISOP stacks are connected in parallel at the input and in series at the output, forming an input parallel connected output series connected (IPOS) system [see Fig. 1(b)]. Each ISOP system also contains an active balancing circuit (DC-Bi) [8], [9], which equalizes the dc-link voltage V DL,i at the input of the SPRC-Bm after each pulse. The active balancing circuit is shown in Fig. 3(a) and (b). This circuit acts as a buck converter where V DL1 is the input voltage and V DL2 is the output voltage, in case V DL1 > V DL2. In contrast, it acts as a buck converter with V DL2 as input voltage and with V DL1 as the output voltage if V DL1 < V DL2.IGBTsare used for the buck converter because of the hard switching and the 800-V dc-link. To keep the control simple, the balancing circuit is operated at the fixed frequency f bal and the fixed duty cycle D bal in discontinuous conduction mode (DCM). All component values as e.g. the dc-link capacitor C DL,i and the buck inductance L DL values are given in Table III. The input voltage charging unit (IVCU) is based on an industrial power factor correction (PFC) boost converter [12] with an ac-to-dc efficiency > 98%. It is connected to a B. Single SPRC-Bm Components The single SPRC-Bm [see Fig. 4(a)] consists of a watercooled full bridge with four semiconductor switches each with six MOSFETs in parallel. The required series inductance L S is realized by the sum of the leakage inductance of the transformer L σ and an external inductance L T [7]. Due to the high switching frequency of 100 to 110 khz and the high resonant peak current of up to 1200 A peak, an air toroid has been designed for the external inductance L T in order to keep the losses low and to avoid saturation effects. The 21 turns winding is made of three parallel connected litz wires each with 6390 mm mm strands. The series capacitance C S is implemented by a single double layered printed circuit board with 896 series/ parallel-connected NP0 dielectric ceramic capacitors. The 896 capacitors have low losses, are stable over a wide range of temperatures and frequencies and also do not suffer from dc voltage derating. The parallel capacitance C P [see Fig. 4(b) and (c)] is made of 216 series- and parallel-connected ceramic capacitors of the same type of capacitors as the series capacitance. The influence of the stray capacitance C d of the transformer is not considered in the design of C P, because it is negligible (see Table II). The series parallel connection of k component parts results in a low total tolerance s(k) = s 1 / k,wheres 1 is the tolerance of each of the k-components. This is mandatory for parallel- and series-connected SPRC-Bm systems, because the component tolerances are significantly influencing the transfer characteristic of the SPRC-Bms and could lead to unequal power sharing between the parallel-connected SPRC-Bms [8], [9]. The output rectifier depicted in Fig. 4(b) consists of 144 diodes in total, where one diode branch consists of 36 diodes. Each diode branch is made of two printed circuit boards due to the high output voltage. The schematic of the output rectifier is depicted in Fig. 4(c) at the left side and has the same basic behavior as the standard rectifier circuit at the right side. In the left-hand side circuit, the parallel capacitor C P acts as resonant tank element, as a filter at the output of the rectifier, and it is additionally utilized to symmetrize the rectifier diodes voltages. The high voltage and high frequency (HV-HF) transformer is shown in Fig. 4(d). Litz wire is used for the primary and secondary winding and ferrite as core material due to the high switching frequency. The isolation of the transformer is designed with respect to the full output voltage of 115 kv due to the series connection of the SPRC-Bms. The turns ratio N

5 JARITZ AND BIELA: SYSTEM DESIGN AND MEASUREMENTS OF A 115-kV/3.5-ms SOLID-STATE LONG-PULSE MODULATOR ESS 3235 Fig. 5. (a) Averaged loss distribution. (b) Volume distribution of a single SPRC-Bm. TABLE II OPTIMIZATION RESULTS OF A SINGLE SPRC-BM AND OPTIMAL NUMBER OF MODULES Fig. 4. (a) Single SPRC-Bm consisting of the full bridge with six MOSFETs in parallel for each switch, the series capacitance C S,andthe series inductance L S. (b) Output voltage rectifier and parallel capacitance C P. (c) Schematics of the output rectifier with identical input-to-output behavior. The parallel capacitor C P is additionally used for the voltage balancing of the rectifier diodes in the configuration on the left side compared with the standard circuit on the right side. One diode branch consists of 36 diodes in series with 6 capacitors in series and in parallel for each diode. (d) High voltage high frequency transformer. of the transformer is N S : N P = 20. The detailed design of the HV-HF transformer is presented in [10]. Fig. 5(a) shows the loss distribution and Fig. 5(b) shows the volume distribution of a single SPRC-Bm. The main losses are generated in the switches due to the high conduction losses caused by the high resonant current. Due to the high isolation voltage of 115 kv, the volume of the transformer is the largest one compared with the other module components, as can be seen in Fig. 5(b). In the following, a critical temperature evaluation of the transformer is given.

6 3236 IEEE TRANSACTIONS ON PLASMA SCIENCE, VOL. 46, NO. 10, OCTOBER 2018 TABLE III PARAMETERS AND COMPONENT VALUES OF THE ACTIVE BALANCING CIRCUIT TABLE IV OPERATION POINT AND TEMPERATURES OF THE TEST TRANSFORMER Fig. 6. Simplified thermal equivalent circuit of the SPRC-Bm transformer, which is shown in Fig. 4(d). IV. TRANSFORMER TEMPERATURE EVALUATION Due to the required high isolation voltage of the transformer (115 kv), it is not possible to directly measure the critical temperatures inside the transformer during normal operation. Therefore, the critical transformer temperatures as for example the temperatures inside the core and the surface of thecore(t 1 and T 4 ) and the temperatures inside the windings (T 2 and T 3 ) are estimated with the validated thermal model given in Fig. 6, which is derived in [13] and [14]. It includes the convective heat transfer from the core and/or the winding surfaces to the ambient (R c-amb, R ws-amb,andr wp-amb )and the conductive heat transfer inside the transformer, which is represented by the thermal resistors of the windings, the core and the bobbins (R ws, R wp, R cl, and R wp-ws ). The losses of the windings and the core are modeled by equivalent current sources (P cr, P cl, P wp,andp ws ). The model has been verified with measurements of the transformer temperatures, where the transformer has been operated at a reduced output voltage V sec of 3.04 kv in air without isolation oil. The measurement system was a Flir ThermoVision A320 thermal camera [15] and the calculated temperature values have a maximal deviation of +12.5% compared with the measured values as presented in [13]. By replacing the thermal parameters of air with the parameters of the isolation oil given in [16], all critical temperatures during normal operation can be determined with the model. In order to determine the ambient (oil) temperature T amb, which is required for the thermal model, a PT1000 temperature sensor [17] is used inside the oil tank. The final oil temperature settles at approximately 60 C after a heat run test of 7(2/3) h, where both modulator systems from Fig. 1(a) are dissipating the transformer and rectifier losses into the oil. The systems were operated with two separate water-cooled resistive loads (2 4.6 k) at nominal pulse conditions (see pulse specifications in Table I). The oil is cooled by an oil to water heat Fig. 7. Measured oil temperature T tank,m inside the tank of Fig. 1(a) and the exponentially fit curve T tank,bf, which is used for extrapolation until a stable temperature is reached. exchange system with a water inlet temperature of 21.5 C and a water outlet temperature of 27.9 C. Fig. 7 shows the measured oil temperature data T tank, m, which is used for fitting to the exponential curve T tank,bf to estimate the steady state temperature of the oil. Table IV shows the calculated temperatures of the transformer, the calculated thermal resistor values for the thermal model and the estimated losses of the windings and the core. A worst case ambient temperature of 65 C (measured ambient temperature of 60 C plus a margin of 5 C) is used for the calculations. All critical temperatures are below 110 C, which is the allowed maximal temperature. V. MEASUREMENT RESULTS In the following, the measured output voltage pulse is evaluated with regard to the pulse specifications are given in Table I. A. Dynamic Pulse Perfomance The modulator system is designed for a nominal output voltage of 115 kv. The switching frequency is starting at

7 JARITZ AND BIELA: SYSTEM DESIGN AND MEASUREMENTS OF A 115-kV/3.5-ms SOLID-STATE LONG-PULSE MODULATOR ESS 3237 Fig. 9. Zoom of the flat-top of the measured output voltage pulse V out given in Fig. 8(a). In addition, the measured averaged output voltage pulse V out,avg (green line) is shown. The blue part of the flat-top is used for determining the ripple spectrum. Fig. 8. (a) Measured output voltage pulse V out (blue line) and averaged output voltage pulse V out,avg (green line). (b) The zoomed-in view of the beginning of the pulse shows the achieved rise time t rise = μs. (c) The zoomedin view of the end of the pulse shows the achieved fall time t fall = μs. The areas K 1 and K 2 represent the part of the transferred energy, which could not be used in the klystron load khz at the beginning of the pulse and is ending at khz in order to compensate the decreasing dc-link capacitor voltage. Fig. 8(a) shows a measured output voltage pulse, where V out (blue line) is the output voltage and V out,avg (green line) is the averaged voltage pulse, which is used for calculating the rise time t rise and the fall time t fall.the SPRC-Bms are working interleaved with an interleaving angle κ and κ k,m = (k 1)π K + (m 1)π MK (1) k =[1...K ], m =[1...M] (2) where each ISOP stack consists of K = 2 SPRC-Bms and M = 9 of this ISOP stacks are connected in series forming the IPOS system. The rise time is t rise = μs (0...99% of V K )[see Fig. 8(b)] and the fall time is t fall = μs ( % of V K ) [see Fig. 8(c)]. Both times are well below the given limits in Table I. The pulse efficiency η pulse is the ratio between the ideal rectangular and the real pulse with limited rise and fall time [18] ( ) Kideal η pulse = 100% = 96.78% (3) with K real K ideal = V K (t 1 t rise ) (4) K real = t2 0 V out dt. (5) The areas K 1 [see Fig. 8(b)] and K 2 [see Fig. 8(c)] represent the part of the transferred energy, which is lost\cannot be used because the klystron load can just be initiated at a certain high voltage level [4]. After the pulse dynamics, the ripple of the output voltage pulse in Fig. 8(a) is evaluated in the following. B. Output Voltage Ripple Evaluation Fig. 9 shows a zoomed region of the flat-top of the measured output voltage pulse of Fig. 8(a). The blue part, which starts

8 3238 IEEE TRANSACTIONS ON PLASMA SCIENCE, VOL. 46, NO. 10, OCTOBER 2018 Fig. 11. Averaged loss distribution of the full-modulator system including the losses of 18 SPRC-Bms, the IVCU, and the pulse shape losses. The resulting efficiencies are listed in Table V. TABLE V SYSTEM EFFICIENCY Fig. 10. Ripple spectrum of the analyzed output voltage pulse in Fig. 9. (a) Full spectrum from 0 Hz to 6 MHz. (b) Zoomed-in view of the spectrum from 0 Hz to 1 MHz. (c) Zoomed-in view of the spectrum from 0 Hz to 10 khz. The main ripple frequency of the output voltage of a single SPRC-Bm is around 200 khz. The yellow area indicates the maximum allowed peak to peak ripple voltage for each frequency component, according to Table I. at t rise and ends at t 1, is used for calculating the ripple spectrum and results in the lowest resolvable frequency component f 1 of Hz with 1 f 1 =. (6) t 1 t rise The measured data is sampled at a rate of 250 MS/s and has been processed with a moving average filter with a cutoff frequency of 104 khz resulting in V out,avg. This resulting averaged voltage gives a good indication for the low frequency ripple during the flat-top (see Fig. 9). The resulting output voltage ripple spectrum is depicted in Fig. 10, where an overview is given for the full spectrum from 0 to 6 MHz [Fig. 10(a)], from 0 to 1 MHz [Fig. 10(b)] and for the low frequency range from 0 to 1 khz [Fig. 10(c)]. It is clearly visible that all frequency components are well within the yellow area, which indicates the maximum allowed peak-to-peak ripple voltage for each frequency component (see Table I). The main switching frequency is around 100 khz, and because of the full wave output rectifier, the main output voltage ripple frequency of a single SPRC-Bm is around 200 khz. Despite the interleaving of all SPRC-Bms, also multiples of the 200 khz appear in the spectrum below khz due to the component tolerances. Fig. 11 shows the averaged loss distribution of the full-modulator system, including the losses of 18 SPRC-Bms, the IVCU, and the pulse-shape losses. The main losses occur in the SPRC-Bms, but also the nonideal pulse shape (see Fig. 8) results in about a third of the losses.

9 JARITZ AND BIELA: SYSTEM DESIGN AND MEASUREMENTS OF A 115-kV/3.5-ms SOLID-STATE LONG-PULSE MODULATOR ESS 3239 Table V lists the achieved system performance. The designed system easily fulfills the global pulse specifications from Table I and achieves an electrical system efficiency η elec,sys of 91.9% and a pulse system efficiency η pulse,sys of 89%, which also considers the losses of the nonideal pulse shape. For the entire system 18 SPRC-Bm (2 9 units connected in parallel) are required. VI. CONCLUSION In this paper, a long-pulse modulator prototype system is presented and a detailed description of the measured pulse parameters is given. Two SPRC-Bms connected in series at the input and in parallel at the output forming an ISOP stack. To generate the given output voltage of 115 kv, nine of this ISOP stacks are connected in series. A detailed description of each SPRC-Bm component is presented. Due to the high operating frequency and the high resonant current, litz wire is used as a winding material for the inductive components and six MOSFETs are connected in parallel, forming a switch in each submodule to keep the losses low. All critical temperatures of the transformer stay well below 110 C, with an assumed worst case isolation oil temperature of 65 C. The measured output voltage pulses are well within the given specification. The achieved rise time of μs andthe achieved fall time of μs result in a pulse efficiency of 96.78%, an overall electrical system efficiency of 91.9% and a pulse system efficiency of 89%, taking also the losses due to the nonideal pulse shape into account. REFERENCES [1] M. Kempkes, K. Schrock, R. Ciprian, T. Hawkey, and M. P. J. Gaudreau, A klystron power system for the ISIS front end test stand, in Proc. IEEE Int. Vac. Electron. Conf., Apr. 2009, pp [2] I. S. Roth, R. Torti, M. P. J. Gaudreau, and M. A. 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Power Electron., Elect. Drives, Autom. Motion, Jun. 2012, pp Michael Jaritz (M 17) was born in Graz, Austria, in He received the Dipl.-Ing. degree in electrical engineering from the Graz University of Technology, Graz, in His diploma thesis dealt with dc voltage link inverters in a power range of 500 kw. In 2011, he joined the High Power Electronics Laboratory as a Ph.D. Student, where he is focusing on series-parallel resonant converters which are used in long pulse modulators generating highly accurate voltage pulses. Juergen Biela (S 04 M 06 SM 16) received the Diploma (Hons.) degree from Friedrich-Alexander- Universitaet, Erlangen-Nuernberg, Germany, in 1999, and the Ph.D. degree from the Power Electronic Systems Laboratory (PES), ETH Zurich, Zürich, Switzerland, in 2006, with a focus on optimized electromagnetically integrated resonant converters. He dealt, in particular, with resonant dc-link inverters with the University of Strathclyde, Glasgow, U.K., and the active control of seriesconnected integrated gate-commutated thyristors with the Technical University of Munich, Munich, Germany, during his studies. In 2000, he joined the Research Department of Siemens Automation and Drives, Erlangen, Germany, where he was involved in inverters with very high switching frequencies, SiC components, and electromagnetic compatibility. From 2006 to 2007, he was a Post-Doctoral Fellow with PES and a Guest Researcher with the Tokyo Institute of Technology, Tokyo, Japan. From 2007 to 2010, he was a Senior Research Associate with PES. Since 2010, he has been an Associate Professor of high-power electronic systems with ETH Zurich. His current research interests include the design, modeling, and optimization of PFC, dc dc and multilevel converters with emphasis on passive components, and the design of pulsed-power systems and power electronic systems for future energy distribution.