Post on 27-Jun-2020
SIRIUS Power Converters:
Test of pre-series converters
Guillermo Navarro Patrón
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• Received one converter of each type.
• Qualification tests.• Visual inspection – Completed on all converters.
• Functional test – Completed on all converters.
• Heat run test – Completed on all converters.
• Performance test – Completed on SIRIUS-S and SIRIUS-2P.
• SIRIUS-4P: IGBT failure event under investigation. Possible infant failure.• Read functional test.
• Verify operation.
• Performance test.
• Production of SIRIUS-S ongoing according to plan.• 25 units in production. First delivery mid October.
• Storage space has been prepared in building 250.
• Qualification test platform for series equipped in building 287.• Building temporary unavailable for construction. Available in October.
Qualification tests
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Current status in factory
Sub-assembly of power converter parts
room
Assembly of power converters room
SIRIUS Power Converters:
Tester for series reception
Guillermo Navarro Patrón
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Flexibility.
One tool for all SIRIUS configurations.
Automation of test tasks.
No need for FGC3 crate.
User friendly and intuitive.
To be operated by factory personnel.
Standard connections (BURNDY).
Tests performed automatically.
Safe. Low voltage operation.
Portable.
Tester features
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Tester features
Architecture
HMI +
Interface
connections
PXI
Interface
board
Power source
output
Hardware integration
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PXI
PXI-8108: Controller. Enhanced with 4GB RAM and 128GB SSD.
PXI-4110: Power supply powering Interface board. Controlled from TestStand.
PXI-6509: Digital I/O. Controlled from LabVIEW.
PXI-6225: Analog I/O. Controlled from LabVIEW.
Interface board
Precharge relay control checked.
MCB manual operation checked.
IGBTs control checked.
Correct data acquisition checked.
Power source
Controlled with LabVIEW and TestStand.
Hardware integration
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TestStand:
Sequence manager.
Synchronization of LabVIEW VI’s.
Creation of results report.
GUI execution.
LabVIEW:
Execution of steps/instructions.
Monitoring variables.
Activating digital inputs.
Communication with TestStand.
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Test implementation
LabVIEW: Interface board
Single PWM Generation
Analog signals readout
Digital outputs command
Full H-Bridge PWM Generation
Digital inputs status readout
Data acquisition.
Data representation.
Filtering noise.
PWM generation.
Commanding switches.
Sending data and
commands to
TestStand.
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Test implementation
Three/Single-phase
configuration
Power source initialisation
Current level setup
Output activation
Output protection configuration
Output Voltage Mode
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LabVIEW: Power source control
Initialising source.
Configure output
protection.
Configure phase
mode output.
Set voltage and
current limits.
10V and 0.1A
Output activation.
Output values
measurement.
Test implementation
Main sequence:
· Main configuration
· Calls every test.
· Clean up.
· Main GUI call
Test sequences:
· One per test.
· Calls every VI.
· Test GUI.
TestStand
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Test implementation
Tests performed
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Test execution
100.000 - Digital interlocks
100.001 - MCB operation
100.002 - Boost Switch
100.003 - Fast Discharge Switch
100.004 - DC Link charge
100.005 - HB11 and HB22 switches
100.006 - HB12 and HB21 switches
100.007 - Crowbar operation
100.008 - Filter damping
100.009 - DCCTs operation
100.010 - Earth detection
Report
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Test execution
Test responsible operator information.
Date and time.
Total execution time.
Pass/Faill status of the whole sequence.
Actions/Steps executed and done.
Steps individual time.
Pass/Fail status of every test.
Measurement values.
Waveforms display.
Conclusion.
Current status
Hardware tested and fully verified with SIRIUS converters
Software implementation:
Sequences for testing digital interlocks implemented and verified.
Sequences for testing DC-Link Precharge implemented and verified.
Sequences for testing H-Bridge implemented and verified.
Debugging minor errors.
What’s next?
Compact even more the platform for easier transport and operation:
Trip to Electrotel (Romania):
Training of the responsible personnel of testing.
Start testing first batch of SIRIUS-S power converters.
Coordination and documentation of the qualification tests at CERN.
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