Progress on the 140 KV, 10 Megawatt Peak, 1 Megawatt Average Polyphase Quasi-Resonant Bridge, Boost Converter/Modulator for the Spallation Neutron Source (SNS) Klystron Power System

TL;DR

This paper presents the design and operational features of a zero-voltage-switching, high-power polyphase boost converter/modulator for klystron applications in the SNS, emphasizing efficiency and innovative use of materials.

Contribution

It introduces a novel zero-voltage-switching polyphase converter with advanced materials and control techniques for high-power klystron pulse generation.

Findings

Achieved zero-voltage-switching of IGBTs at 20 kHz

Demonstrated effective energy storage with polypropylene capacitors

Validated design through computer, scale model, and initial tests

Abstract

This paper describes electrical design and operational characteristics of a zero-voltage-switching 20 kHz polyphase bridge, boost converter/modulator for klystron pulse application. The DC-DC converter derives the buss voltages from a standard 13.8 kV to 2300 Y substation cast-core transformer. Energy storage and filtering is provided by self-clearing metallized hazy polypropylene traction capacitors. Three "H-Bridge" IGBT switching networks are used to generate the polyphase 20 kHz transformers primary drive waveforms. The 20 kHz drive waveforms are chirped the appropriate duration to generate the desired klystron pulse width. PWM (pulse width modulation) of the individual 20 kHz pulses is utilized to provide regulated output waveforms with adaptive feedforward and feedback techniques. The boost transformer design utilizes amorphous nanocrystalline material that provides the required low core loss at design flux levels and switching frequencies. Resonant shunt peaking is used on the transformer secondary to boost output voltage and resonate transformer leakage inductance. With the appropriate transformer leakage inductance and peaking capacitance, zero-voltage-switching of the IGBT's is attained, minimizing switching losses. A review of these design parameters and a comparison of computer calculations, scale model, and first article results will be performed.