x-band solid state modulator development...x-band solid state modulators page 16 . x-band solid...

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

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


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)


SLAC Induction Modulator Development

Larger IGBT heat sink

37.5µF @4.3 kVcapacitors

Table-top 2-Pack


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


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


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



NLC DFM1 Hybrid Modulator

Larger IGBT heat sink


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


ORION 5045 Klystron Modulator


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


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


Other Development: ScandiNova (K2-3X)

• Long rise/fall time, ~2 µs (265kV / 262A) – Large effective

turns ratio, >400:1

– 1 kV cells


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


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 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

x-band solid state modulator development...x-band solid state modulators page 16 . x-band solid...

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