Post on 19-Jan-2021
X-band Solid State Modulator Development
Craig BurkhartPower Conversion Department
January 5, 2011
Overview• Inductive adder topology• SLAC development
– SLAC team:• Richard Cassel (SLAC slide material)• Minh Nguyen• Ed Cook (LLNL)• Craig Brooksby (NSTec)
• Other development• ScandiNova• Sincrotrone Trieste• DTI
X-Band Solid State Modulators Page 2
Inductive Adder Topology• Modules with transformer coupled
output– Primaries in parallel– Secondaries connect in series
• Array low voltage IGBTs to generate high voltage pulse
• Single turn (or few turn) transformers have high bandwidth
• All components at near ground potential
• Fault tolerant
T
1/3/1
C1 ,2
2 x5 0 ufd 2 .5 kv
Q1
3.3Kv 800A
C3
1 30 ufd 1 5 0vD13 kv
GE
C
DRV1
IGBT DRI
T
1/3/1
C1 ,2
2 x5 0 ufd 2 .5 kv
Q1
3.3Kv 800A
C3
1 30 ufd 1 5 0vD13 kv
GE
C
DRV1
IGBT DRI
T
1/3/1
C1 ,2
2 x5 0 ufd 2 .5 kv
Q1
3.3Kv 800A
C3
1 30 ufd 1 5 0vD13 kv
GE
C
DRV1
IGBT DRI
T
1/3/1
C1 ,2
2 x5 0 ufd 2 .5 kv
Q1
3.3Kv 800A
C3
1 30 ufd 1 5 0vD13 kv
GE
C
DRV1
IGBT DRI
T
1/3/1
C1 ,2
2 x5 0 ufd 2 .5 kv
Q1
3.3Kv 800A
C3
1 30 ufd 1 5 0vD13 kv
GE
C
DRV1
IGBT DRI
X-Band Solid State Modulators Page 3
SLAC Induction Modulator Program1. XP(8-Pack): Driving eight PPM klystron (XP)
500kV 2000A (500MW RF) 1.6 μsec 120 Hz for RF Program.(Tested with water load, XP klystron did not get manufactured)
2. XL4(4-Pack): Driving four XL4s using one half the drivers 400kV 1260A (200MW RF) 1.6 μsec 30-60 Hz for RF Testing. (Operated)
3. DFM (Design For Manufacturing) (8-Pack):Design a prototype, to Drive 8 XP klystrons (Program change klystron reduced to 2 Klystrons per modulator)
4. DFM1 (Hybrid 2-Pack): Build a DFM prototype 15 stack and drive (2) XL4 klystrons using an existing 1:10 pulse transformer 400kV 630A 3.2 μsec. (Operational)
5. DFM (Integrated 2-Pack): Design and build a DFM Modulator using 12 turn secondary transformer to drive 2 XP klystrons (Project change to ILC, design never completed)
X-Band Solid State Modulators Page 4
SLAC Induction Modulator Development
Larger IGBT heat sink
37.5µF @4.3 kVcapacitors
Table-top 2-Pack
X-Band Solid State Modulators Page 5
8/4-Pack Table-top
3.3 kV IGBT 6.5 kV IGBT
NLC 8-PACK (8-XP) MODULATOR
5045 Klystron400 kV, 450 Amps
CORES AND SECONDARY76 Primaries @ 5400 A3 Turn Secondary400 kV @ 1800 A, 725 Meg watts for 3.2µs, 350 kW Ave.
Water Load500 kV, 650 Amps
SOLID STATE DRIVERS152 IGBT’s Drivers
(two per Primary)1800 volts per IGBT2700 Amps per Driver
X-Band Solid State Modulators Page 6
NLC 4-PACK (4-XL4) MODULATOR
XL4 Klystrons400kV @ 320 A1.6 μsec
controls
drivers
Klystron supplies
(4) XL4 Klystrons400kV 1200A
CORES AND SECONDARY76 Primaries @ 5400 A3 Turn Secondary400 kV @ 1200 A,
SOLID STATE DRIVERS76 IGBT’s Drivers 1800 volts per IGBT3600 Amps per Driver
X-Band Solid State Modulators Page 7
Table-top (6575 Equivalent) Modulator
C 11 0
G rE m
G R+ 1
C o
D R
I G B
2
3
Q 1
2
0 .
2
C 1
5 0
D 8 kT
1
C 21 0
G rE m
G R+ 1
C o
D R
I G B Q 2
2 e
C 2
5 0
D 8 kT
1
C 31 0
G rE m
G R+ 1
C o
D R
I G B Q 3
2
C 3
5 0
D 8 kT
1
C 11 0
G rE m
G R+ 1
C o
D R
I G B Q n
2
C n
5 0
D 8 kT
1
+
+
+
+
6
5 3
P
1
3
1 2 0
(Note: Rise time slow due to pulse transformer leakage inductance and stray capacitance)
10 Primaries @ 5400 A20 IGBT drivers
2.2 kV, 2.7 kA1 Turn Secondary1:15 conventional X-former
330 kV, 360 A
X-Band Solid State Modulators Page 8
X-Band Solid State Modulators Page 9
NLC DFM1 Hybrid Modulator
Larger IGBT heat sink
37.5µF @4.3 kVcapacitors
DFM1 Hybrid modulator utilizing DFM fabricated parts; 15 Metglas cores, 30 IGBT drivers, with a single secondary turn driving a conventional 1:10 pulse transformer: 530kV, 600A, 1.6 μsec, 120 Hz
Water Load 500kV 500A
(2) XK4 Klystrons400kV 440A
X-Band Solid State Modulators Page 10
ORION 5045 Klystron Modulator
37.5µF @4.3 kVcapacitors
1 >
2 >
1) Iout 200A/V: 5 VOL 500 nSEC 2) Vout 1kV/V: 5 VOL 500 nSEC
8 cells @ 24kV, 6kA
Resistive load 4 ohms 30nFModulator only 24kV 6000A
8 Primaries @ 6210 A16 IGBT drivers: 3.0 kV, 3.1 kA1 Turn Secondary1:15 conventional X-former: 360 kV, 414 A
DFM2 2-Pack Design (not fabricated)
ModularCap Chargers
ModularCap Chargers
0
15.254
DFM2 prototype to drive 2 ea XP klystrons using single 15:150 ratio pulse transformer 30 drivers 500kV 500A 1.6 μsec. 120 Hz, Low leakage inductance, small size
X-Band Solid State Modulators Page 11
Other Development: ScandiNova
• Commercial manufacturer of “fractional turn” modulators (topologically equivalent to SLAC DFM2)
• K2 model to – 0.15 GWpeak
– 0.1 MWave
– 0.5 MV– 4 kA– ± 0.05% pulse flatness– ± 0.002% stability
X-Band Solid State Modulators Page 12
Other Development: ScandiNova (K2-3X)
• Long rise/fall time, ~2 µs (265kV / 262A) – Large effective
turns ratio, >400:1
– 1 kV cells
X-Band Solid State Modulators Page 13
Other Development: ST-Fermi
• Prototype modulator (S-band) developed for Sincrotrone Trieste Fermi FEL project
• Based on SLAC design• Not completed• Prototype transferred
to CPI
X-Band Solid State Modulators Page 14
Other Development: Diversified Technologies, Inc.
• Hybrid hard-tube– 80 kV solid-state switch (IGBT) – ~1:6.33 transformer– SLAC Klystron Test lab
• NLC Marx– 12.5 kV cells (IGBT stack)– 9-cell prototype (1/5th scale)– Project terminated after down-
select to SC
X-Band Solid State Modulators Page 15
X-Band Solid State Modulators Page 16
X-Band Solid State Modulator Status
• IGBT-based solid state modulators are capable of meeting (and exceeding) the high power klystron requirements
• Commercial availability• R&D opportunities to improve efficiency,
fault tolerance, and modulator lifetime– Optimized IGBT switch– High voltage, high bandwidth adder design