Pulsed Power Control System - Requirements

General:
- 19 inch rack mount controller to handle all control system requirements of the pulsed power system
- System consists of HV PSU, HV capacitor bank, solid state switch, connecting coaxial cables and in-vacuum Helmholz coil
assembly

Personnel safety:
- Key switch to enable located on controller
- Emergency machine off button circuit with multiple buttons (one on controller)
- Prevention from charging via disconnect from HV PSU and PSU interlock
- Discharge of stored energy via dump resistor circuit
- Monitoring of 5x capacitor pressure (switch)
- Beacon and warning siren indicating hazard that charging is enabled/dump is disconnected
- Beacon indicating that device is safely discharged and isolated
( for local testing lab):
- Safety gate preventing access closer than 2 m distance from the apparatus

Machine safety:
- Control over the proper firing sequence using the MSS FPGA sequencer
- Disconnection of HV PSU before firing
- Reliable prevention of firing until armed

Other issues:
- Interference (EMC) with other devices, injection to mains power, and pickup by other device in vacuum chamber

TEMPLATE
STA
DESIGN
TUS

PPCS – System interface overview DEVICES

NON-SAFETY
SYSTEMS
MACHINE
SAFETY
PERSONNEL
SAFETY
24V
DIGITAL
ANALOG POWER OPTICAL SERIAL
SYSTEMS SYSTEMS SIGNALS CIRCUITS TRIGGERS DATA
SIGNALS

PPS
CAGE

KEY 10000:1
WARNING CAPACITOR EMERGENCY
MONITORED ENABLE CAPACITOR TRIGGER CAPACITOR CAPACITOR HIGH VOLTAGE POWER
STATUS PRESSURE MACHINE OFF
SAFETY GATE PERMISSIO VOLTAGE THYRATRON DUMP RELAY CHARGE RELAY SUPPLY
BEACON SWITCHES (X5) BUTTONS
N DIVIDER (X2)

COI COI
L L
24V I/O 24V I/O 24V I/O TRIGGER
SERIAL
FEEDBACK FEEDBACK
CONTROL

INTERLOCKE
D POWER
PPCS
Charge
PROTECTION Pressure Charge
Voltage State dump Charge Charge PRIMARY CIRCUIT
CIRCUIT & switch Fire relay HV PSU
measuremen signallin release dump relay MAINS
THRESHOLD monitori trigger comman control
t g comman feedback position CONTACTORS
RELAYS ng d
d

VOLTAGE < 40V CONTACTORS

PERMISSION
OPEN FEEDBACKPERMISSION
FEEDBACK LOOP FEEDBACK FEEDBACK
LOOP
DISTRIBUTION DISTRIBUTION DISTRIBUTION
PP PSS
PLC
Pressure
Warning No high Charge Charge Charge Enable EMO
Access Key switch Disabled
indicatio voltage permissi relay relay permissv monitori
Control Enable monitori feedback
n detected ve position position e ng
ng

PPS CONTROL
BOX PERMISSION PERMISSION
E3 LOOP LOOP

HALL
E3 HALL
MSS
State Charge
signallin permissi
g ve

CONTACTORS
VOLTAGE < 40V
OPEN
E3 HALL PSI (ROCKWELL)
No high Enable
Disabled
voltage permissi
feedback
detected ve

TEMPLATE
STA
DESIGN
TUS

PPCS – Basic HV Circuit

PPS P3
HIGH VOLTAGE
CAGE PRESSURE SENSOR CAPACITOR BANK CHAMBER
TECSIS 5X ELECTRONICON
S4150B071808 E59.E53-543010
ISEG HIGH VOLTAGE HV RELAY 1 DRY PUR
POWER SUPPLY (CHARGE ENABLE
DISCHARGE DISCHARGE: PEAK
MAINS CONTACTOR CIRCUIT)
CURRENT CURRENT 50kA,
2 HV BUSBAR
MAINS CONTACTOR MONITORING DURATION ms COIL TARGET
THYRATRON
1 HVR1 C1 C2 C3 C4 C5 TRANSFORMER (CIRCUIT MODEL)
KM5 KM5 VOLTAGE
HV RELAY 2
HVPS801 MONITORING TH1 CT2 HIGH VOLTAGE
A B 230 (CHARGE DUMP
POTENTIAL COAXIAL CABLES
CIRCUIT)
VAC DIVIDERS
1PH SUPPLY
54u 54u 54u 54u 54u
15 kV VT1 VT2 HVR2 DUMP RESISTOR 60mΩ
F F F F F
NETWORK
CUSTOM 40uH
FEEDTHROUGH

RN1 CR1 R1

0R4
20R

CROWBAR
DIODE
PE BOND
GROUND BUSBAR

PPS CONTROL
BOX

TEMPLATE
STA
DESIGN
TUS

PPCS – Power Wiring

PPS CONTROL
20A RATING PHNX UT 4-HESILED
Terminal
BOX
TYPE C Termin Termina 24 (5X20) GY -

FA5 FV1 6A RATING TYPE C al l block 3074172 block DPWR

SALTEK DA-275
DFi6 FA51 block N PE G51 FAST BLOW
MW SDR-120-24 5A / 120 W
1PH SUPPLY 1 2 L1 L1 1 2 L + F1 F5A 24V.1
N N +V
PE CONTINUED
PE V
-V COM.1 Terminal
CRIO801: E3 VCS
-V
N N 11 block IOM.1
12 24V.1 A 1
PE PE 24V.1 1
A ?? 1 1/32 NI
6A RATING TYPE C ??
G52
2 4 2A? D?? 9425 POWER SUPPLIES GOOD
FA52 5A / 120 W Sinking DI
USE SHIELDED MW SDR-120-24
MAINS CABLE. 1 2 L + F2 F5A 24V.2
N N +V CONTINUED
TERMINATE SHIELD PE V
PE -V COM.2
AT ENTRY TO -V
CABINET 11
12

6A RATING TYPE C
FA53 G53
MW SDR-120-24 5A / 120 W
PE BOND F3 F5A
1 2 L + 24V.3
N N +V
PE PE V
-V COM.3
MINIMUM 16 MM2
-V
‘DIRTY’ GROUND ‘CLEAN’ GROUND
11
DC POWER CIRCUITS
12 DC CIRCUIT 1: RIO & MODULES
CABINET
6A RATING TYPE C DC CIRCUIT 2: PLC & MODULES
METALWORK
FA54 G54 DC CIRCUIT 3: FIELD SENSORS
5A / 120 W
IMPORTANT: SEPARATE EXTERNAL MW SDR-120-24
1 2 L + F4 F5A 24V.4 DC CIRCUIT 4: FIELD CONTROL
EQUIPOTENTIAL BOND SHALL BE USED TO KM5A KM5B N N +V
ABB AFS09Z ABB AFS09Z PE V (INTERLOCKED)
CONNECT CABINET METAL AND EXTERNAL CABLE -30-22-30 -30-22-30
PE -V COM.4
USE SHIELDED
-V
SHIELD BONDING. THIS IS THE ‘DIRTY’ GROUND 11 MAINS CABLE.
12 COM.1
TERMINATE SHIELD
AT ENTRY TO HVPS801
6A RATING TYPE C ISEG 15kV
Terminal CABINET
FA55 L1 T1 L1 T1 FLT51
PHNX 3x1.5 1-CYKFY-J
2788977 block HVPS.1
1 2 L2 T2 L2 T2 L L 1
N N N 2
L3 T3 L3 T3 PE PE PE 3

SURGE PROTECTION Terminal

PHNX 2906829
CONTINUED CONTINUED block SPD.1
3 1
1 12v
PE 4 2
3 1
2 12v
4 2
3 1 24V.2
3 12v
4 2
3 1 COM.2
4 12v
4 2
3 1 24V.3
5 12v
4 2
3 1 COM.3
6 12v
4 2
3 1 24V.4
7 12v
4 2
3 1 COM.4
8 12v
4 2

N
PE

CLEAN GROUND CONNECTS TO INTERNAL

MOUNTING PLATE

TEMPLATE
STA
DESIGN
TUS

PPCS – EMO Circuit PPS CONTROL

Terminal
BOX
EMO1
PILZ PIT es
Set1s-6
block DPWR
3 1 24V.3
1
4 2 COM.3

FRONT-PANEL 3 1 24V.3
2
4 2 COM.3
MOUNT EMO
BUTTON
REMOTELY
MOUNTED BUTTONS
(ON CAGE). NUMBER
TBD

EMO..n EMO2.. Terminal

block EMO.1
WH 1
BN 2
GN 3
CONTINUED
YE

PP PSS: PLC8??
4

1 ½ PSSu
WH 3 1
4
5
2
1 1A? DO0E F ENABLE_PERMISSIVE_CH1
2
3 ½ PSSu
2DOR 8
BN 3 1
4
6
2
1
3 1A? DO1E¼F ENABLE_PERMISSIVE_CH2
21 2DOR
GN 3 1 PSSu 8
4
7
2
2
1 1A1 DI0 E-STOP PRESSED
1 EF
YE 3 1 4DI
8
4 2
PHNX UT 4-HESILED
CONTINUED
Terminal 24 (5X20) GY -
EXTERNAL PSI 3074172
block PSI.1 FAST BLOW
INTERFACE
PERMISSION TO OPERATE CH1 OUT WH 1 FUSE
BN 100mA
1 FUSE
PERMISSION TO OPERATE CH1 GN 100mA
3
RETURN YE 4

PERMISSION TO OPERATE CH2 OUT WH 1 FUSE

BN 100mA
1 FUSE
CONTINUED
PERMISSION TO OPERATE CH2
RETURN
GN 100mA
7 Terminal
YE 8 Terminal
GY 9 block IOM.1
block DPWR PPCS: CRIO8??
DISABLED FEEDBACK CH1
PK 10 A 1 1/32 NI
GY 11 ??
DISABLED FEEDBACK CH2
PK
1
A 1 1 2A? D?? 9425 E-STOP PRESSED
12 COM.2 2
A 4
1 COM.1 1/32 NIDI
?? Sinking
24V.3 1
A 2 1 2A? D?? 9425 POWER SUPPLY ENABLED
COM.3 2 4 COM.1
Sinking DI
CONTINUED CONTINUED
ORANGE INTERLOCK
CONTINUED
WIRING (ENERGIZED KM5A KM5B
ABB AFS09Z ABB AFS09Z
WHEN CABINET IS -30-22-30 -30-22-30
ISOLATED) A2 A1 A2 A1

13 14 13 14

21 22 21 22

31 32 31 32

43 44 43 44
CONTINUED

PP PSS: PLC8?? ¼
1
PSSu
2
1 1A1 DI0 ¼ DISABLED CH1
1 EF
PSSu
2
1 1A1 DI0 4DI DISABLED CH2
1 EF
4DI

CONTINUED

TEMPLATE
STA
DESIGN
TUS

PPCS – VT Circuit PPS CONTROL

EXCERPT FROM VOLTAGE DIVIDER DATASHEET
BOX
Terminal Terminal CONTINUED
Terminal
block DPWR block DPWR
3
block IOM.?
1 ??
PPCS:
1/4 NI 9222
CRIO8??
4
1
2 ?? 2A? ai?? VT1 INPUT
Isolated AI
3 1 ?? 1/4 NI 9222
4
2
2 ?? 2A? ai?? VT2 INPUT
Isolated AI

Terminal
block IOM.1
A 1 1/32 NI
24V.3 1
A 3 1 24V.1 2A? D?? 9425 LVS1 NO HV DETECTED
??
2
A 4
1 1/32 NIDI
Sinking
1
A 4 1
?? 2A? D?? 9425 LVS2 NO HV DETECTED
2 4 Sinking DI
LOW DRIFT DC
REGULATOR. TYPE IS
CONTINUED
TBD

DCDC2 DCDC1
102320018
V
2V PHNX

+ + + + CONTINUED
24V.3
- - - -

PP PSS: PLC8??
24 COM.3
10 V
V
¼
1
PPS SIL2 CAPABLE 2
1
1
1A? DI?
PSSu
¼
EF
HIGH VOLTAGE
UNDETECTED CH1
Max voltage 15 kV = PSSu HIGH VOLTAGE
LIMIT VALUE 1A? DI? 4DI
CAGE
2
1
1.5V PHOENIX CONTACT 1 EF UNDETECTED CH2
Safe voltage <40V = SWITCHES MACX MCR-T-UIREL- 4DI
TERMINATE SHIELD
HV BUSBAR 4mV UP - 2811378 CONTINUED
HV AT ENTRY TO
CABINET
VT1 LVS01 3.
Terminal 5. 5
3.
1GΩ COAXIAL OR TRIAXIAL
1 6
2.
V DC
CABLE
block VTS.1 5
2.
3 1 6
1.
1
100kΩ 4 2 5
1. COM.3
5. +V
CO
5
1.
POT1 2 2 2
1.
PHNX 2811378
M 1
3
HV ADJUST UNTIL 4
RTN 10k
RESPONSE CURVE
OFFSET IS CORRECT 5 Terminal EXTERNAL PSI
PHOENIX CONTACT LVS02 block PSI.2 INTERFACE
VT2 EMG 30-SP-10K LIN - 6 3. 1 WH HIGH VOLTAGE UNDETECTED CH1
7 5. 5
3. 2 BN
2942124 8 1 6
2. 3 WH
1GΩ HIGH VOLTAGE UNDETECTED CH2
5
2. 4 BN
V DC 3 1 6
9 1.
COAXIAL OR TRIAXIAL
4 2 BIDIRECTIONAL TVS 5
1. COM.3
100kΩ CABLE
5. +V
CO
5
1.
DIODE, 5V NOMINAL 2 2
1.
(OR LESS, IF PHNX 2811378
M 1
HV AVAILABLE).
RTN
E.G., LITTELFUSE
SA5.0CA

Vdetect = HV/10k Vdetec

1GΩ 1GΩ
R1 + t SPL+1. Response curve
VT1 = HV/10k + VP/2*(R2-R1/R1+R2)
H VP/2
5V
VT2 = HV/10K – VP
V VP/2
2V NOMINAL
100kΩ 100kΩ
R2

BAD SPL+4
SPH mV
SINGLE FAULT-TOLERANT DIAGNOSTIC CIRCUIT GOO
1) Apply floating VProbe across voltage dividers to detect disconnection from probes or potential
SPL D POT1 unbalance = live zero
divider failure BAD
2) Aim to detect High Voltage < 40 V (HV/10k < +/- 4mV) 0V adjust HV (V)
3) If one probe fails or disconnects, circuit will be imbalanced
0V 40V 15 kV
- If VT1 disconnects, Vdetect = +VP/2
- If VT2 disconnects, Vdetect = -VP/2
4) Slightly unbalance R1/R2 potentiometer to create positive switch point (live zero)
5) Detect good region between live zero and 40 V TEMPLATE
STA
DESIGN
TUS

PPCS – HV Relay Circuit PPS CONTROL

BOX
PPS Terminal Terminal
block DPWR block DPWR
CAGE NOTE: WITH THIS
RELAY TYPE IT IS
NOT POSSIBLE TO
Terminal
Terminal EXTERNAL MSS
MOUNT FEEDBACK block MSS.2
block MSS.1
CONTACTS FOR THE
DE-ENERGIZED
24V.4
1
1 1
A
1
A 24V.3 INTERFACE
4 2 1 CHARGE PERMISSIVE
POSITION. COM.3 2
HVR1 THEREFORE FAILURE
OF RETURN SPRING
IS NOT DIAGNOSED
(DANGEROUS
FAILURE)
HV PSU HV BUSBAR

MICROSWITCH FOR
NOT CLOSED ENERGIZED CONTINUED
POSITION
CLOSED
1
PP PSS: PLC8?? ½ PSSu
1 1A? DO0E F CHARGE_PERMISSIVE_CH1
Terminal 2
3 ½ PSSu
2DOR 8
1
3 1A? DO1E F CHARGE_PERMISSIVE_CH2
block HVR.1 COM.4 2 2DOR 8
3 1
1
4 2
3 1
2 ¼
4 2
1
3 PSSu HVR1 CAPACITORS NOT
CHARGE NOT CLOSED
2
1 1A? DI? ¼
4 1 EF CONNECTED
PSSu HVR1 CAPACITORS
CHARGE CLOSED
2
1 1A? DI? 4DI
¼F
5 1 E CONNECTED
PSSu HVR2 DUMP CIRCUIT NOT
2
1 1A? DI? 4DI
¼
EF RELEASED
HVR2 1
PSSu HVR2 DUMP CIRCUIT
2
1 1A? DI? 4DI
1 EF RELEASED
4DI
HV BUSBAR DUMP CIRCUIT CONTINUED

MICROSWITCH FOR
NOT
ENERGIZED
RELEASED
POSITION
RELEASED

Terminal
block HVR.2 CONTINUED
3 1
1
4 2
3
4
2
1
2
PPCS: CRIO8??
3
4 DUMP NOT RELEASED

5 DUMP RELEASED
Terminal
block IOM.1
A 1
CHARGE NOT CLOSED 1
A 5 1 24V.1 1/32 NI
?? HVR1 CAPACITORS NOT
CHARGE CLOSED
2
A 4
1 2A? D?? 9425
1
A 6 1 1/32 NIDI CONNECTED
?? Sinking HVR1 CAPACITORS
DUMP NOT RELEASED
2
A 4
1 2A? D?? 9425
1
A 7 1 1/32 NIDI CONNECTED
?? Sinking HVR2 DUMP CIRCUIT NOT
DUMP RELEASED
2
A 4
1 2A? D?? 9425
1
A 8 1 1/32 NIDI RELEASED
?? Sinking HVR2 DUMP CIRCUIT
COM.2 2 4 2A? D?? 9425
RELEASED
Sinking DI

Terminal
block IOM.2
1 A 1/32 NI
1 1 1
A 24V.1 2A? D?? 9477 HVR1 – ENABLE CHARGING
?? 1/32 NI
4
1 2
A Sinking DO HVR2 – ISOLATE DUMP
1 2 1
A
?? 2A? D?? 9477
4 2 CIRCUIT
Sinking DO

CONTINUED

TEMPLATE
STA
DESIGN
TUS

PPCS – Capacitor Pressure Monitoring Circuit

PPS PPS CONTROL

CAGE BOX

CONTINUED
C1
1
Terminal PP PSS: PLC8??
3 block CPS.1 1
¼
2 3 1 PSSu CAPACITOR PRESSURE
4
1
2
2
1 1A? DI?
1 EF CIRCUIT GOOD
4DI

CONTINUED

C2 Terminal Terminal
1 block DPWR block DPWR
3
2 Terminal CONTINUED
block IOM.1
A 1
24V.1
PPCS: CRIO8??
1
A 9 1 1/32 NI
COM.2 ?? CAPACITOR PRESSURE
2 4 2A? D?? 9425
C3 Sinking DI
CIRCUIT GOOD

1
3 CONTINUED
2

C4
1
3
2

C5
1
3
2

TEMPLATE
STA
DESIGN
TUS

PPCS – CT Circuit

TEMPLATE
STA
DESIGN
TUS