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HUGHES
HUGHES AIRCRAFT COMPANY AEROSPACE GROUP
SPACE SYSTEMS DIVISION
EL SEGUNDO CALIFORNIA
QUARTERLY TECHNICAL REPORT
PERIOD I JULY - 30 SEPTEMBER 1968
ELECTRIC THRUSTER POWER CONDITIONER
CONTRACT NO 952297
HUGHES AIRCRAFT COMPANY
EL SEGUNDO CALIFORNIA
QUT Zl 1)38
W JgYMuldoon Assistant Project Manager
J A Robertson ontract Administrator
This work was performed for the Jet Propulsion Laboratory
California Institute of Technology as sponsored by the National Aeronautiis and Space Administration under Contract NAS 7-100
This report contains information prepared by the
Hughes Aircraft Company under JPL subcontract
Its ontent is tot necessarily endorsed by the
Jet Propulsion Laboratory California Institute of
Technology or the National Aeronautics and Space
Administration
ABSTRACT
Quarterly report on JPL Contract 952297 for a 20 C Electric
Thruster Power Conditioner and Support Equipment presents circuit
and physical design description efficiency analysis reliability
analysis and test data taken on preliminary breadboards
Report discusses techniques of high-efficiency regulation and
control ie single inverter pulse-width modulation staggeredshy
phase inverter modulation line-regulator modulation magnetic
modulation Design goal efficiency is 93 percent Preliminary
tests suggest this is feasible-
Techniques of analog thruster loop control are discussed also
overload trips standby and active redundancy
Report also discusses physical design approach for self-radiating
cooling
TABE OF CONTENTS
Page
INTRODUCTION 1
TECHNICAL DISCUSSION 2
1 General 2
a Objectives 2
b System Description 2
2 Pulse-Width Modulation Techniques 6
a Single Inverter Modulation 6
b Staggered Phase Modulation
12
-d Magnetic Modulation I
c Line Regulator Modulation i
3 Cathode RMS Current Regulatorl
4 D C Voltage Regulation i
a Arc Supply is
b Accelerator Supply 21
c Screen System 21
5 System Control Techniques 22
a General 2
b Command Controls 24
c Overload-Trips 2f
d Analog Controls 2E
e Standby Controls 2E
6 Test Data 41
a Low Voltage Group 41
b Power Inverter 41
c Cathode Supply 41
d Function Generator 41
e Components 41
f Analog Controls 41
iii
Page
7 Efficiency Analysis 62
a Screen Inverter 62
b Arc Inverter 66
c Acceletator Inverter 67
d Cathode Inverter 68
e 5 KHz Inverter 70
f 5 KHz Line Regulator 70
g Accelerator Line Regulator 72
h Arc Rectifier Filter 73
i High Voltage Filter 73
j Magnetic Modulator 74
k Summary of Losses 75
8 Reliability Analysis 76
9 Physical Design 99
a General 99
b Support Structure 100
c Module Assemblies 100
d Miscellaneous Considerations 105
10 Power Conditioner Support Equipment - Test Console 112
a General 112
b FunctionalCircuit Description 113
c HardwarePackaging Description 117
d Energy Needs and Losses 117
11 Calorimeter 134
12 List of Drawings 136
INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
15 EE
Supply I Name
440~-5VmTRange
Current
_0_V _aneOf
Voltage
High Accuracy Part T Rane
Current Voltage
Shutdown Levels
(Note 1 Low High
I
3
Masnot
Vapor
Cathi Ktr
03- 09A
0 - 3A
10 shy 45A
----
065 - 075A
----
4- Arc 0 - 7A 30- 40V 2- 7 - 36V
5
6
7
B
Beam
Accelj
lNeutr Hitr
Neutr Keeper
0 - IA
0 - 2OmA
0 - 4A
0 - IA
1700 - 2100
1700 - 2100
-
0 - 30
05 -IA
aa
--
1950 - 2050
1950 - 2050
shy
1750V
1
Z750V
-ashy
t2 1 0 0 V
2
2100V
Neutr Emission 0 - IA
ff a- 5V Output
Areingamp 10 AreMmn
NTZ It At these livels P vil be ordered to shut-down
Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
-II
i7fl iY- -S
Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
allet 2r F-
-2A
Z3O
3V0 a
-o o4
E
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rpc -shy
3v ---J
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A a Z PAVE I4
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S IL
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7 IL
)z L
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=9 tp
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c I V4
Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
- ---- -
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
251 404
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Power Transistor Switching Speeds
Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
25 25 10
26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
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Interval Inverters Required at
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1 7
2 6
3 5
The reliability Probability of meeting these requirements for
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edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
S1EEN 5CREEN 5CPEFN RF__N INV INV INV INV
it I -2 3k 4
9ow 1- w 19o w k9ow -o-l WIN 2 C27W IN 027 W IN o-z2W ItN
zsdegc 25 5C -c
Sr-CRIMEN SCREEN SC-9EEN sCRkEEN INV INV INV INV
11o w 19 ow le)o w 13 0w 02- WIN 012- WIN 0 2 7 WIN2 027 W IN
asoc zswC cC2C -
ACCEL ARC KH C H 0O DE
INV INV INV INV
4 W 4) IS2WI SW OW IN 03al WIN 2ISWINL 02 wINL
I V ARC LINE RE CONTROL
swIILTR5Iw bcFMILR - RCT OSW105) MWDs L
013 WIN Z lOW02SWIN 2 0 7 WINz25C
0 1WIN22o 0 C
za00c 2s 0 ~C
i-V MAlG LINE LOW VOL-rcE TERMINaL M0)DUL ATO RFI- (ACCEL) TEMINL BO ARDk 4ampW 4 W ESOaRD
c O W OowIN
0 10 WIN Z00 C
0 10 wIN
OO 00 OW
WIN
T-TOTAL LvOS Z31uA3 Ar7S-To-AL- ArLEA= 1ofo3 w
AVJEtLUtO-rSIU= 0--Z5 AULRamp-TtAPZ 2-30 C
THERMAL MAP F 5-1 ULSTI i cLU-Tpound P -vZr- 9( 06)
d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
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HUGHES
HUGHES AIRCRAFT COMPANY AEROSPACE GROUP
SPACE SYSTEMS DIVISION
EL SEGUNDO CALIFORNIA
QUARTERLY TECHNICAL REPORT
PERIOD I JULY - 30 SEPTEMBER 1968
ELECTRIC THRUSTER POWER CONDITIONER
CONTRACT NO 952297
HUGHES AIRCRAFT COMPANY
EL SEGUNDO CALIFORNIA
QUT Zl 1)38
W JgYMuldoon Assistant Project Manager
J A Robertson ontract Administrator
This work was performed for the Jet Propulsion Laboratory
California Institute of Technology as sponsored by the National Aeronautiis and Space Administration under Contract NAS 7-100
This report contains information prepared by the
Hughes Aircraft Company under JPL subcontract
Its ontent is tot necessarily endorsed by the
Jet Propulsion Laboratory California Institute of
Technology or the National Aeronautics and Space
Administration
ABSTRACT
Quarterly report on JPL Contract 952297 for a 20 C Electric
Thruster Power Conditioner and Support Equipment presents circuit
and physical design description efficiency analysis reliability
analysis and test data taken on preliminary breadboards
Report discusses techniques of high-efficiency regulation and
control ie single inverter pulse-width modulation staggeredshy
phase inverter modulation line-regulator modulation magnetic
modulation Design goal efficiency is 93 percent Preliminary
tests suggest this is feasible-
Techniques of analog thruster loop control are discussed also
overload trips standby and active redundancy
Report also discusses physical design approach for self-radiating
cooling
TABE OF CONTENTS
Page
INTRODUCTION 1
TECHNICAL DISCUSSION 2
1 General 2
a Objectives 2
b System Description 2
2 Pulse-Width Modulation Techniques 6
a Single Inverter Modulation 6
b Staggered Phase Modulation
12
-d Magnetic Modulation I
c Line Regulator Modulation i
3 Cathode RMS Current Regulatorl
4 D C Voltage Regulation i
a Arc Supply is
b Accelerator Supply 21
c Screen System 21
5 System Control Techniques 22
a General 2
b Command Controls 24
c Overload-Trips 2f
d Analog Controls 2E
e Standby Controls 2E
6 Test Data 41
a Low Voltage Group 41
b Power Inverter 41
c Cathode Supply 41
d Function Generator 41
e Components 41
f Analog Controls 41
iii
Page
7 Efficiency Analysis 62
a Screen Inverter 62
b Arc Inverter 66
c Acceletator Inverter 67
d Cathode Inverter 68
e 5 KHz Inverter 70
f 5 KHz Line Regulator 70
g Accelerator Line Regulator 72
h Arc Rectifier Filter 73
i High Voltage Filter 73
j Magnetic Modulator 74
k Summary of Losses 75
8 Reliability Analysis 76
9 Physical Design 99
a General 99
b Support Structure 100
c Module Assemblies 100
d Miscellaneous Considerations 105
10 Power Conditioner Support Equipment - Test Console 112
a General 112
b FunctionalCircuit Description 113
c HardwarePackaging Description 117
d Energy Needs and Losses 117
11 Calorimeter 134
12 List of Drawings 136
INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
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2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
-II
i7fl iY- -S
Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
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26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
bull92998 I 999994 I
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2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
136
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This report contains information prepared by the
Hughes Aircraft Company under JPL subcontract
Its ontent is tot necessarily endorsed by the
Jet Propulsion Laboratory California Institute of
Technology or the National Aeronautics and Space
Administration
ABSTRACT
Quarterly report on JPL Contract 952297 for a 20 C Electric
Thruster Power Conditioner and Support Equipment presents circuit
and physical design description efficiency analysis reliability
analysis and test data taken on preliminary breadboards
Report discusses techniques of high-efficiency regulation and
control ie single inverter pulse-width modulation staggeredshy
phase inverter modulation line-regulator modulation magnetic
modulation Design goal efficiency is 93 percent Preliminary
tests suggest this is feasible-
Techniques of analog thruster loop control are discussed also
overload trips standby and active redundancy
Report also discusses physical design approach for self-radiating
cooling
TABE OF CONTENTS
Page
INTRODUCTION 1
TECHNICAL DISCUSSION 2
1 General 2
a Objectives 2
b System Description 2
2 Pulse-Width Modulation Techniques 6
a Single Inverter Modulation 6
b Staggered Phase Modulation
12
-d Magnetic Modulation I
c Line Regulator Modulation i
3 Cathode RMS Current Regulatorl
4 D C Voltage Regulation i
a Arc Supply is
b Accelerator Supply 21
c Screen System 21
5 System Control Techniques 22
a General 2
b Command Controls 24
c Overload-Trips 2f
d Analog Controls 2E
e Standby Controls 2E
6 Test Data 41
a Low Voltage Group 41
b Power Inverter 41
c Cathode Supply 41
d Function Generator 41
e Components 41
f Analog Controls 41
iii
Page
7 Efficiency Analysis 62
a Screen Inverter 62
b Arc Inverter 66
c Acceletator Inverter 67
d Cathode Inverter 68
e 5 KHz Inverter 70
f 5 KHz Line Regulator 70
g Accelerator Line Regulator 72
h Arc Rectifier Filter 73
i High Voltage Filter 73
j Magnetic Modulator 74
k Summary of Losses 75
8 Reliability Analysis 76
9 Physical Design 99
a General 99
b Support Structure 100
c Module Assemblies 100
d Miscellaneous Considerations 105
10 Power Conditioner Support Equipment - Test Console 112
a General 112
b FunctionalCircuit Description 113
c HardwarePackaging Description 117
d Energy Needs and Losses 117
11 Calorimeter 134
12 List of Drawings 136
INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
15 EE
Supply I Name
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Current Voltage
Shutdown Levels
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
-II
i7fl iY- -S
Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Losses in 300 Watt Inverter
Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
251 404
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Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
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2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
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26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
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Interval Inverters Required at
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1 7
2 6
3 5
The reliability Probability of meeting these requirements for
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d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
S1EEN 5CREEN 5CPEFN RF__N INV INV INV INV
it I -2 3k 4
9ow 1- w 19o w k9ow -o-l WIN 2 C27W IN 027 W IN o-z2W ItN
zsdegc 25 5C -c
Sr-CRIMEN SCREEN SC-9EEN sCRkEEN INV INV INV INV
11o w 19 ow le)o w 13 0w 02- WIN 012- WIN 0 2 7 WIN2 027 W IN
asoc zswC cC2C -
ACCEL ARC KH C H 0O DE
INV INV INV INV
4 W 4) IS2WI SW OW IN 03al WIN 2ISWINL 02 wINL
I V ARC LINE RE CONTROL
swIILTR5Iw bcFMILR - RCT OSW105) MWDs L
013 WIN Z lOW02SWIN 2 0 7 WINz25C
0 1WIN22o 0 C
za00c 2s 0 ~C
i-V MAlG LINE LOW VOL-rcE TERMINaL M0)DUL ATO RFI- (ACCEL) TEMINL BO ARDk 4ampW 4 W ESOaRD
c O W OowIN
0 10 WIN Z00 C
0 10 wIN
OO 00 OW
WIN
T-TOTAL LvOS Z31uA3 Ar7S-To-AL- ArLEA= 1ofo3 w
AVJEtLUtO-rSIU= 0--Z5 AULRamp-TtAPZ 2-30 C
THERMAL MAP F 5-1 ULSTI i cLU-Tpound P -vZr- 9( 06)
d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
118 - v -I1
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
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ABSTRACT
Quarterly report on JPL Contract 952297 for a 20 C Electric
Thruster Power Conditioner and Support Equipment presents circuit
and physical design description efficiency analysis reliability
analysis and test data taken on preliminary breadboards
Report discusses techniques of high-efficiency regulation and
control ie single inverter pulse-width modulation staggeredshy
phase inverter modulation line-regulator modulation magnetic
modulation Design goal efficiency is 93 percent Preliminary
tests suggest this is feasible-
Techniques of analog thruster loop control are discussed also
overload trips standby and active redundancy
Report also discusses physical design approach for self-radiating
cooling
TABE OF CONTENTS
Page
INTRODUCTION 1
TECHNICAL DISCUSSION 2
1 General 2
a Objectives 2
b System Description 2
2 Pulse-Width Modulation Techniques 6
a Single Inverter Modulation 6
b Staggered Phase Modulation
12
-d Magnetic Modulation I
c Line Regulator Modulation i
3 Cathode RMS Current Regulatorl
4 D C Voltage Regulation i
a Arc Supply is
b Accelerator Supply 21
c Screen System 21
5 System Control Techniques 22
a General 2
b Command Controls 24
c Overload-Trips 2f
d Analog Controls 2E
e Standby Controls 2E
6 Test Data 41
a Low Voltage Group 41
b Power Inverter 41
c Cathode Supply 41
d Function Generator 41
e Components 41
f Analog Controls 41
iii
Page
7 Efficiency Analysis 62
a Screen Inverter 62
b Arc Inverter 66
c Acceletator Inverter 67
d Cathode Inverter 68
e 5 KHz Inverter 70
f 5 KHz Line Regulator 70
g Accelerator Line Regulator 72
h Arc Rectifier Filter 73
i High Voltage Filter 73
j Magnetic Modulator 74
k Summary of Losses 75
8 Reliability Analysis 76
9 Physical Design 99
a General 99
b Support Structure 100
c Module Assemblies 100
d Miscellaneous Considerations 105
10 Power Conditioner Support Equipment - Test Console 112
a General 112
b FunctionalCircuit Description 113
c HardwarePackaging Description 117
d Energy Needs and Losses 117
11 Calorimeter 134
12 List of Drawings 136
INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
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Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
25 25 10
26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
bull92998 I 999994 I
94223
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IN V
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9522
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bull99 994
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99223
)16~4zeCC
-324
998679 87
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t
Az ( 411-h3 4
999839
199938 A Y24
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q
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LVlj
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t
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iszacK
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=(U-F4S 0 -cs li- SY T S14 (P6 =
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9
1p CA7XeZ dampTAAT FIJQ-W
2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
136
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TABE OF CONTENTS
Page
INTRODUCTION 1
TECHNICAL DISCUSSION 2
1 General 2
a Objectives 2
b System Description 2
2 Pulse-Width Modulation Techniques 6
a Single Inverter Modulation 6
b Staggered Phase Modulation
12
-d Magnetic Modulation I
c Line Regulator Modulation i
3 Cathode RMS Current Regulatorl
4 D C Voltage Regulation i
a Arc Supply is
b Accelerator Supply 21
c Screen System 21
5 System Control Techniques 22
a General 2
b Command Controls 24
c Overload-Trips 2f
d Analog Controls 2E
e Standby Controls 2E
6 Test Data 41
a Low Voltage Group 41
b Power Inverter 41
c Cathode Supply 41
d Function Generator 41
e Components 41
f Analog Controls 41
iii
Page
7 Efficiency Analysis 62
a Screen Inverter 62
b Arc Inverter 66
c Acceletator Inverter 67
d Cathode Inverter 68
e 5 KHz Inverter 70
f 5 KHz Line Regulator 70
g Accelerator Line Regulator 72
h Arc Rectifier Filter 73
i High Voltage Filter 73
j Magnetic Modulator 74
k Summary of Losses 75
8 Reliability Analysis 76
9 Physical Design 99
a General 99
b Support Structure 100
c Module Assemblies 100
d Miscellaneous Considerations 105
10 Power Conditioner Support Equipment - Test Console 112
a General 112
b FunctionalCircuit Description 113
c HardwarePackaging Description 117
d Energy Needs and Losses 117
11 Calorimeter 134
12 List of Drawings 136
INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
15 EE
Supply I Name
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Current
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High Accuracy Part T Rane
Current Voltage
Shutdown Levels
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NTZ It At these livels P vil be ordered to shut-down
Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
-II
i7fl iY- -S
Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
allet 2r F-
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
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26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
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Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
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Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
118 - v -I1
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11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
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7 Efficiency Analysis 62
a Screen Inverter 62
b Arc Inverter 66
c Acceletator Inverter 67
d Cathode Inverter 68
e 5 KHz Inverter 70
f 5 KHz Line Regulator 70
g Accelerator Line Regulator 72
h Arc Rectifier Filter 73
i High Voltage Filter 73
j Magnetic Modulator 74
k Summary of Losses 75
8 Reliability Analysis 76
9 Physical Design 99
a General 99
b Support Structure 100
c Module Assemblies 100
d Miscellaneous Considerations 105
10 Power Conditioner Support Equipment - Test Console 112
a General 112
b FunctionalCircuit Description 113
c HardwarePackaging Description 117
d Energy Needs and Losses 117
11 Calorimeter 134
12 List of Drawings 136
INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
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Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
25 25 10
26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
bull92998 I 999994 I
94223
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IN V
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9522
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bull99 994
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99223
)16~4zeCC
-324
998679 87
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t
Az ( 411-h3 4
999839
199938 A Y24
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q
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LVlj
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t
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iszacK
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=(U-F4S 0 -cs li- SY T S14 (P6 =
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9
1p CA7XeZ dampTAAT FIJQ-W
2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
136
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INTRODUCTION
The objective of this contract is the design and fabrication of a power
conditioning and control system for the JPL 20 cm electric thruster which
requires approximately 3 KW of conditioned power with prime power from a
solar array ranging from 40 volts out to 80 volts out
The requirements of 1 regulation on all outputs and a wide range of
control combined with a target efficiency of 93 and a weight at eight
pounds per kilowatt necessitates the use of pulse-width modulation on all
supplies The large step-up for high voltage dc supplies and large
step-down for high current low voltage ac supplies requires the use
of dc to ac inverters
To satisfythe requirements of high efficiency and low weight inverters
must operate at relatively high frequency The choice of transistors
with the high speed switching required for high efficiency is limited to
20 amp rating usable at f0 amp for reliability At 40 volt low line the
resultant limit is 400 watts per inverter ( paralleling transistors is
costly in efficiency due to need for equalizing techniques) Hence in one
supply requiring an output of 2000 volts at I amp (2 K-W) the total power
must be obtained from a group of inverters For high efficiency with wide
range of regulation and control to avoid the losses associated with separate
modulation and inversion pulse-width modulated inverters are used
In this first three month period in the contract principal efforts were in
the design and development of the subsystems and circuits required by the
system The results of this development effort are described in this
report with emphasis on technology rather than description of the detailed
embodiment of the techniques described although detailed circuits are
presented to illustrate the reduction to practice of these techniques
TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
5-29-68 5aa L3-4 7amp 91 4o 8 2
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Supply I Name
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Current Voltage
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
-II
i7fl iY- -S
Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
allet 2r F-
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Losses in 300 Watt Inverter
Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
251 404
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Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
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2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
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26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
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Interval Inverters Required at
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1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
S1EEN 5CREEN 5CPEFN RF__N INV INV INV INV
it I -2 3k 4
9ow 1- w 19o w k9ow -o-l WIN 2 C27W IN 027 W IN o-z2W ItN
zsdegc 25 5C -c
Sr-CRIMEN SCREEN SC-9EEN sCRkEEN INV INV INV INV
11o w 19 ow le)o w 13 0w 02- WIN 012- WIN 0 2 7 WIN2 027 W IN
asoc zswC cC2C -
ACCEL ARC KH C H 0O DE
INV INV INV INV
4 W 4) IS2WI SW OW IN 03al WIN 2ISWINL 02 wINL
I V ARC LINE RE CONTROL
swIILTR5Iw bcFMILR - RCT OSW105) MWDs L
013 WIN Z lOW02SWIN 2 0 7 WINz25C
0 1WIN22o 0 C
za00c 2s 0 ~C
i-V MAlG LINE LOW VOL-rcE TERMINaL M0)DUL ATO RFI- (ACCEL) TEMINL BO ARDk 4ampW 4 W ESOaRD
c O W OowIN
0 10 WIN Z00 C
0 10 wIN
OO 00 OW
WIN
T-TOTAL LvOS Z31uA3 Ar7S-To-AL- ArLEA= 1ofo3 w
AVJEtLUtO-rSIU= 0--Z5 AULRamp-TtAPZ 2-30 C
THERMAL MAP F 5-1 ULSTI i cLU-Tpound P -vZr- 9( 06)
d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
118 - v -I1
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
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TECHNICAL DISCUSSION
1 General
a Objectives
The broad objectives are to design a system providing the outputs
shown in Tables I and II with -prime power from a solar array varying from
40 V to 80 V such as obtained on a Jupiter mission (40 V at earth 80 V
at Jupiter) The 6ystem weight should not exceed 235 pounds and efficiency
should not be less than 92 Reliability for a 10000 hour flight should
exceed 96
Start-up and shut-down shall be commanded by pulse signals of
20 V to 31 V of 20 milliseconds duration at 75 mA
Control of thruster screen current shall be by an analog signal with
5 volts for I amp continuously variable to 05 amps at 0 volts control
Telemetry shall be supplied as indicated in Table II at anormalized
full-scale output of 5 volts at a source impedance of 10K ohms or less
b System Description
All voltages delivered by the Power Conditioning System delineated
in Table I are derived from inverters operating at two synchronized
frequencies ie 125 KHz and 5 KHz Individual inverters deliver power
in the range of 100 to 300 watts Where higher power is required such as
the screen system at 2 KV and 1A total power is derived from the series
output of 300 watt inverters
By restricting the maximum output per inverter to 300 watts it is
possible to use high speed transistors and thereby retain high efficiency
at reasonably high frequency such as 125 KHz permitting low weight and
high efficiency transformers Further advantages from the modularization are
adaptability to fractional redundancy for high reliability and adaptability
to staggered phasing to minimize ripple from pulse-width regulation The
staggered phase technique also minimizes the peaking of the screen ntput
-filters at no load
The 5 KHz inverter frequency is used for ac heater loads where a
higher frequency would result in excessive line and load inductive impedance
4 MacRatings Nominal Ratings Range of Frequency v ii-i - shy
ply spl R 1 fk Control2) 4 RippLIN P u i 5) Output RippleGroup Supupply Type
No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
5mA 30V 5 at lOVr (4- - -n--si - - - - - shy-
2 Vaporizer AC V 10 20 205 55 11 6 Loop --- 05 - 12 5
-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
fl7V -i--i
5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
03 amp
1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
-II
i7fl iY- -S
Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
- ---- -
-
OA ~ C-7 7x
-a tashy-
bull deg
AV)- A
- -
- -- -
-1~
0 1- ell0 04 - -
lt
o o2 04 0418 asg 10 -
As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
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25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
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27 20 10
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57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
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2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
136
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No Name = =I JIi i -
S V A A V A W 7 A kHz kHz
S Magnet Mantfld Htr DC F 19 085 09 15 067 105 10(I) 5 --- --- 10
3 Cath Htr AC V 5 40 45 45 35 160 Loop --- 10 - 40 5
7 Nautr Htr AC V 12 34 4 12 28 35 Loop 03- 34 5
300V 20mA 2 at 30V 8 Neutr Kpr DC F 0o5 10 050 5 10(E) 002-05 --- 10
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-5-1S 7 t36O 2 7 4 Arc DC V 2mA - 8 345 6 210 1O(z) 2 2-7 --- 30
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5 Beam DC V 2050 10 105 2000V 10 2kw 10(E) 5 05-10 --- 30
2050 [13)6 Accel DO P 0105 2000V 001- 20 10(g) 5at --- -30
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1) Output V - Variable F - Fixed
2) Current Limits or overload trips - Exact values to be specified by the manufacturer
3) Current stays at this level for less than 10 minutes at very low rep rate
4) Starting Characteristicsa (150V N to 36V at 20 ma) 5) Current varies as nmetion of engine loop control See Figures below
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Supply I Name
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Current
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High Accuracy Part T Rane
Current Voltage
Shutdown Levels
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Areingamp 10 AreMmn
NTZ It At these livels P vil be ordered to shut-down
Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
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Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
251 404
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Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
25 25 10
26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
58
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
bull92998 I 999994 I
94223
Az3784
IN V
2
2 LyCFlt5) 4 3 Ay(oAv)-4S7
9522
-3 [100o
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srI4 Ifdpound PK [
=9
IA
l2779A
2=Ow-3 --(oA)=3Qo0
p99342 a7h1 6
-- Iml2- -[CoP
A33k
bull99 994
29872 9
Iccd-
A-2
99223
)16~4zeCC
-324
998679 87
A5ZS23
MV 2779
- A S
t
Az ( 411-h3 4
999839
199938 A Y24
99999
q
92835-1
IAIII
LVlj
2 (efCLAV)
-shyraM C824 9986
_____ 2~|
t
4C4tS
5P60dl
FAtzI
WampE c Y X~
AAzV
5 A A1 - xt 5 (io)s Ae~
iszacK
~ centA3te-AI TA
(IC-dj ZIY1
c I11fAAO1 7 xo
=(U-F4S 0 -cs li- SY T S14 (P6 =
-z9702Y
9
1p CA7XeZ dampTAAT FIJQ-W
2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
S1EEN 5CREEN 5CPEFN RF__N INV INV INV INV
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
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Table IIS Telemetry Data and
at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
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Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
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2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
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26 20 08
27 20 10
28 15 08
29 15 06
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Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
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Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
118 - v -I1
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11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
136
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at relatively high currents and low-voltages required It is also used for
low power loads such as Magnet-Supply and Neutralizer Keeper to minimize
circuit complexity
The 125 KHz inverter frequency is used for dc-to-dc converters
at high power (300 watts) for reasons stated above
Referring to Functional Block Diagram Drawing X3188131 regulated dc
voltage of 35 volts is derived from the chopper line regulator which
regulates output within one percent over the rangeof 40 to 80 volt line
A master oscillator serves as the chopping frequency source for the regulator
and as the master oscillator for all pulse-width-regulated inverters Also
derived from the oscillator is synchronized 10 KHz for the 5 KHz heater inverter
and 10 KHz for the cathode heater pulse-width-regulator
The 5 KHz heater inverter supplies square-wave voltage to magneticallyshy
regulated supplies for the Magnet (VI) vaporizer-heater (V2) neutralizer
heater (V7) and neutralizer keeper (V8) supplies Additionally it supplies
regulated dc voltages for driven inverters base drive (cathode arc accelerat
and screen) and for miscellaneous logic and control functions
The cathode arc and screen inverters all use pulse-width modulated
base drive for regulation with prime power derived from the 40 to 80 volt
line
The accelerator inverter is a driven inverter not modulated but
regulated by a chopper line regulator in series with the line and controlled
by feedback from the accelerator supply output This technique was chosen
rather than a modulated inverter in view of the resonant ringing with high
step-up between output filter choke and transformer distributed capacity
the choke necessitated by the modulated inverter By regulating (controlling)
input dc inverter output is square-wave and requires only a small capacity
for filtering minimizing output ringing Such ringing is of course highly
undesirable at the 2 KV level of the output
As mentioned above in discussing the advantages of the modular system
the screen system inverters are stagger-phased The phase shifting required
is accomplished in the oscillator section since this section includes the
master oscillator used as the reference frequency for phase-shifting The
screen inverters are phase-shifted 18 of a half-cycle apart with all inverter
5
dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
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Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
- ---- -
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
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25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
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Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
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Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
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2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
bull92998 I 999994 I
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1p CA7XeZ dampTAAT FIJQ-W
2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
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dc outputs (unfiltered) in series- All inverters are modulated under control
of feedback from the total screen output voltage In event of failure of one
inverter other inverters advance On time to compensate
The cathode arc and accelerator inverters consist of an Operate
and Standby inverter in each supply the Standby being switched on in
event of a failure of the Operate inverter
The Control Section pr6vides the control and telemetry interface with
the vehicle provides the required control link between interdependent supplies
(minor loop gain and transfer function) provides the necessary automatic
sequencing and time delays in turn-on monitors the system for overload
trips controls recycle time senses inverter failures and controls standby
switching It also contains the system master oscillator and phase shifter
Details of the individual circuits will be discussed in later sections
of this review
2 Pulse-Width Modulation Techniques
a Single Inverter Modulation
Referring to System Diagram Drawing X3188131cathode and arc systems
shown use a single operating inverter with a standby inverter Each inverter
is pulse-width modulated for control andor regulation The cathode inverter
operates at 5 KHz and the arc inverter at 125 KHz
In the following discussion reference should be made to schematic of
arc inverter Dwg X3188109
The mode of inverter modulation chosen will maintain accurate balance
on pulse-width of alternate half cycles of carrier thereby minimizing ratcheting
of output transformer from DC unbalance restricting this unbalance to that
due to unequal saturation or unequal storage time of output transistors
Modulation is achieved as follows a modulation carrier of twice
the output frequency (square-wave) is integrated (R26 Cl) to obtain a
triangular wave-form The triangular wave-form is summed with the difference
between output feedback and a reference bias the net difference being applied
to a comparitor amplifier Q15 A small droop error signal will swing the
comparitor trigger from off to on for full half-cycle (see following figure)
6
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Modifications in the conventional drive utilizing a single transformer
ere necessary to accommodate a pulse width modulated drive In the single
ransformer drive circuits a pulse would not be transformed perfectly due to
eakage inductances The secondary overshoots in the negative-direction and
n an ECU application turns the off transistor on for a short period of time
his effect is undesirable and can be overcome by 1) using two drive
ransistors (turn-on and turn-off) directly connected to each of two power
witches (eliminates the transformer) and 2) using two transformers Alternate I
as thoroughly investigated utilizing a variety of designs The major disadshy
antages were power consumption circuit complexity and high failure rate
omponents (power transistor drive)
The circuit chosen is essentially two energy storage converters one
riving each side of the ECU Several advantages result from this configurashy
ion ie low failure rate components (signal transistor drive) low
omplexity and power savings The natural kickback of the transformer is
seful in supplying the needed turnoff bias and with separate transformers
oes not affect the off transistor Also the transformer coupling permits
mpedanee match from a 35 volt drive source to the -2volt base drive The basic
ower drive stage for one-half the ECU is shown in Figure 2-1 The drive pulse
or Q1 of Fig 2-1 is shown and the resulting voltage and current waveforms
re shown for each part of the circuit
Referring to Fig 2-1 upon application of power to the base of QI the
I collector voltage drops to near zero impressing the supply voltage across
he TI primary The voltage appearing at the secondary turns Q2 on During
he conduction period the collector current increases as shown The initial
tep in current is the reflected base current When base drive is removed from
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Qi the stored energy in the transformer causes the voltages to reverse and
CRI clamps the primary Since TI is center tapped the voltage developed at
Qi is twice the supply voltage and the voltage on the secondary is just the
reverse of its previous value The reverse base current is limited by CR2
and Q2 base impedances and when measured was found to be 2 amperes peak
The transistor is thus not subjected to high reverse base-emitter voltages and
a low impedance path is provided to remove the stored charge The commutation
(fly-back) current at turn-off must be large enough to supply the turn-off curshy
rent demand of Q2 when the transformer reverses The peak design collector
current for 100 percent duty cycle is 04 amperes and at 25 percent would be
015 amperes which when reflected to the secondary would be 195 amperes
The system is designed to operate a no less than 50 percent duty cycle
thus adequate turn-off current is assured
A damping network is required to limit the overshoot voltage at Q1
The damping current is seen in Fig 2-i The line current is a composite of
the collector and transformer fly-back currents and is also shown A sketch
of flux density is also given
The drive pulse for Ql is generated by a 932 gate Part of the
gate is used to and the flip-flop output and pulse amplifier output The two
gates are capacitance coupled as shown to prevent destruction of Q3 or Q4 due
to loss of drive signal (Dwg X3188109)
This circuit was breadboarded and optimized with a measured base drive
power of 15 watts per side or 30 watts total drive power for 300 watts out
(10 percent) which is within the design goal for the stage The total weight
of the two drive transformers is 28 grams also within the design goal on weigh
The variable pulse-width output of the comparitor amplifier (see
schematic) is summed with the output from a flip-flop triggered at 2f on
a nand gate Ql Q2 for each phase of the carrier The output of each nand
gate is invertered in a power gate coupling to the driver amplifier Q3 Q4
The output transistor chosen Q5 Q6 is the Solitron SDT 8805 rated
at 325 volts Vcex 300 volts Vcesfst and 20 amps with a minimum beta of 15
10 amps From the published data the expected minimum beta at 8 amps (252
watts out) is 20 required a circuit beta of 15 for good saturation at 8 amps
10
The switching time for the SDT 8805 is less than microsecond
resulting in good switching efficiency at 125 KHz The storage time will be
about I to 2 microseconds which requires compensation when full-on to prevent
overlap of output transistors and resultant output current spikes and high
switching dissipation The compensation method chosen derives a hold-off
bias from an output transformer winding T5 such that the drive on the
lion-coming transistor is held off until the current in the off-going
transistor starts to collapse
Diodes CR39 to CR40 are used to clamp the output transistors to a
voltage close to double line voltage The clamp operates through the tight
coupling of the bifilar-primary the induced voltage due to collapsing current
being-clamped on the opposite side of primary to the voltage on the line
capacitor through the clamping diodes
The operating frequencies of 125 and 5 KHz were chosen as compatible
with a master oscillator and consistent with maximum allowable frequency of
5 KHz for heaters (line drop at low voltage high current and engine heater
inductance) and a frequency for DC-DC converters compatible with high
efficiency and minimum size and weight A discrete jump in size of available
cores for output transformers suggests 125 KHz since the next smaller core
is too small for 252 watts at 15 KC and the core chosen permits operation at
125 KHz at 300 watts hence higher efficiency than that at 15 KHz (higher
switching losses)
The output transformer to be used with the inverter will be a ferrite
cup-core Indiana CF 217-05 material with a 2000C Curie point Tests have
verified that this core will operate at 1400c without saturation at 2 kilogauss
operating flux density a temperature well above the expected maximum of 950C
Core loss was verified as being within the expected 1 of output power Copper
loss was found to be significantly higher (-50) than the DC value due~to skin
effect An approximation analysis using super-position of harmonic currents
verified the measured loss as expected Use of Litz wire multi-filar or
foil windings would result in lower space factor hence is not justified
The choice of ferrite for the output transformer was made on the basis
of low core loss at the frequency desired comparable to that obtained with
1i
nickel-iron I mil tape cores plusthe tolerance in a cup-core of some
dc unbalance inherent in the inverter The residual air-gap in the
cup-core is sufficient to permit a significant dc without excessive
ratcheting A further advantage is the ideal heat-transfer to the mounting
inherent in the cup-core shape
b Staggered Phase Modulation
Referring to Dwg X3188131System Block Diagram and X3188105 Screen
Inverter S6hematic the screen system delivering 2000 volts at 1 amp uses
eight (8) inverters with dc outputs in series each inverter delivering
250 volts or 250 watts
The modulation circuitry used in the screen inverter is similar to
that described abovefor the cathode and arc inverter
To minimize ripple reduce size of ripple filter and improve no-load
to full load regulation each inverter is driven at 125 KHz with phase
displacement of 18 of 12 cycle between inverters resulting in a ripple
frequency of 200 KHz and a maximum peak to peak ripple of 500 volts at 2000
volts unfiltered ie plusmn 250 volts
Dwg No X3188121-2 Master Oscillator and Phase Shifter indicates
the method for obtaining the staggered phase drive for the screen inverters
Fig 2-2 is the timing diagram for this circuit
The digital staggered phase generator (SCPG) is designed to provide
two sets of 125 KHz square waves Each set consists of eight separate
square waves separated by exactly 18 of cycle The two sets of staggered
sqdare waves are then logically combined to produce 16 modulated pulses which
are buffered to provide current drive for the inverter transistors in the ECUs
The 125 KHz staggered square waves are produced by shifting a 125 KHz
square wave through a seven bit shift register at a 200 KHz clock rate The
200 KHz square wave is given for reference The 125 KHz waveform is the
output from the second 16 bit counter in Channel A Channel B is the delayed
channel The outputs from the first four bits of the shift register in
Channel A are shown as 2A 3A 4A
Channel B is a duplicate of Channel A The Channel B counters are
reset at the trailing edge of the pulse width modulator output The pulse
12
width modulator is of standard triangle wavezero crossing type The butput
of the Channel A counter is integrated t6 obtain the triangle waveform The
ramp compared with the control voltage produces the PWM waveform shown
By reseting the B counters at the end of the PWM pulse the
count is effectively delayed by one-half the PWM pulse width By anding
the two shift register outputs a delayed pulse equal in width to the PWM
pulse is obtained for each phase of the system The two required waveforms
for each half of the inverters are shown as El and 2 Fl and 2 Cl and 2
and HI and 2
Since the counters change state only on the fall of the clock pulse
the phase difference between the two counters and hence the shift registers
cat be only increments of one clock pulse This determines the accuracy to
which the pulse width can be controlled To achieve I percent regulation
the clock rate must be at least 200 times the inverter frequency since each
one-half cycle must be controlled to within one perdent Since integer powers
of two are available from binary counters a factor of 256 is used The
oscillator frequency is thus 32 MHz
The square-wave outputs of the phase shifter are anded on the inputs
at the screen inverter input gates to produce the controlled pulse width
The remaining inverter circuitry following the input gates is
identical to that described for the arc inverter except in the output transshy
former rectifier
c Line Regulator Modulation
Referring to System Block DiagramDwgX3188131 it will be noted that
two (2) subsystems the 5 KHz inverter and associated low voltage group and
the accelerator supply use a line regulator
In the case of the 5 KHz inverter and its associated low voltage
supplies the latter use individual load regulators (magnetic-amplifiers) since
the low power required of these supplies permits a lower efficiency and
higher per-unit weight to obtain minimum complexity (high reliability) Hence
the burden of regulation on the line regulator is that of line variation only
The accelerator supply uses its associated line regulator for both
line and load regulation to permit a square-wave inverter for the high
voltage step-up required in the inverter and thereby minimize ringing of
output transformer and simplify filtering at high voltage
The line regulator circuit5 drawing no 3188119 is identical f03
both applications differing only in the voltage sense connection
The regulator is a synchronized switching regulator As a switching
regulator it converts 80 VDC to 40 VDC line variation to a regulated or
controlled nominal 35 VDC with an efficiency of approximately 941 When R4
remote feedback is connected to ground the filter regulated output power
is connected to the local feedback point 10 KHz signal (S6) is Applied to
the modulation signal input and the line power connected to the line power
input the line regulator regulates dc voltage out
The line regulator can also be utilized withremote feedback Such
is the case of the accelerator regulator The connection for this mode of
operation are as follows regulated 35 VDC (from 5 KHz line regulator) to
low voltagereference 10 KHz S6 signal to input modulation signal regulated
output to accelerator inverter input and line power to input power
Circuit Operation Description
Time Zero apply power and S6 10 KHz square wave to proper inputs
Time One current flows through R9 into the base of Q2 Q2 turns Q3
on Q3 turns Q4 on
Time Two the voltage across C4-(S7) rises to 35 VDC and is fed back
to the local feedback connection Note remote feedback is grounded
Time Three the feedback current flows through RI achieving proper
zener current through CRI and CR2 therefore supplying Al with a reference
voltage and power for operation S6 square wave is passed through a low pass
filter and converted into a 10 KHz triangle wave (S8) S7 and SS are summed
together through R5 and R14 to the summing input of Al (Als) Al is utilized
in a high gain switching amplifier configuration
Time Four the voltage at Al summing point equals the reference voltage
Time Five the output of Al switches to plus 18 VDC
Time Six Ql turns on and Q2 Q3 Q4 turn off
Time Seven the current continues to flow through LI therefore CR7
conducts and the voltage at the junction of L and CR7 is minus 7 VDC hence
voltage at the junction of RII and C3 is a minus 7 VDC
I
Time Zero One Two etc equals sequential timing not real time
14
Time Eight CR3 becomes forward biased and charges 03 to +35 VDC
through-Rll
Time Nine the voltage at the sumning point of Al decreases below the
reference voltage
Time Ten the output of Al returns to zero and Qi turns off
Time Eleven Q2 Q3 and Q4 conducts and the voltage at the juntion
point of C3 and RIl increases to1tine voltage plus 35 VDC
Time Twelve the voltage across C3 discharges through RII RIO Q2
Q3 and Q4 therefore creating an efficient drive The voltage at the junction
of R9 andRlO-is line voltage plus 16 V peak Q2 is in supe saturation
CR5 is back biased and Q3 is in hard saturation The voltage across Q4 is
Q3 hard saturation voltage plus Q4 base to emitter voltage
This completes one cycle of regulation
d Magnetic Modulation
Reference to System Block Diagram X318813 and Magnetic Modulator
Schematic Dwg No X3188123 will show that three supplies use magnetic
modulation for load regulation These are 1) Magnet Supply 2) Vaporizer
Supplyi and 3) Neutralizer Heater Supply (the Neutralizer Keeper Supply is
simply reactance current limited)
The magnet supply regulates dc load current while the vaporizer
and neutralizer heater regulate ac load current (RMS regulation) However
the mode of modulation is similar in all 3 systems differing only in current
sense circuits Therefore the following explanationof the magnet modulator
will substantially apply to the other supplies
The magnet supply is required to furnish a regulated dc current at
085 amps at a maximum voltage of 19 volts and is referenced to the screen
+ 2 KV supply
The circuit used here is that of a conventional doubler mag-amp
in series with the primary of the output transformer Current is sensed by
a current transformer in the primary circuit with a peak sensitive filter on
the rectified output of the current transformer
15
The load inductance supplieg the necessary filtering of the pulse-width
modulated output current at 10-KHz fundamental with rich harmonics Consequently
the output current is substantially constant while the average ac current
varies substantially with load impedance While the wave-form of primary
current is substantially exponential rather than square-wave it has been
determined experimentally that a peak current detector provide the necessary
accuracy in current regulation and is a substantially less complex hence
more reliable method than other techniques which might be used on the output
floating at 2 KV (Magnetic transductor Hall effect devices etc)
The current feedback signal is nulled with a reference signal at the
differential transistor The resulting collectorcurrent due to null unbalance
is used to control the mag-amp
The bias winding insures that the mag-amp is driven close to saturation
in absence of a null unbalance signal thus eliminating the control range
which might otherwise be lost due to residual reset
Telemetry is supplied through an isolation resistor permitting a
short in telemetry with only small effect on regulated output (approx 1)
7 volt zener acts asa clamp on possible transients
To minimize effect of temperature on regulation and telemetry the
current sense rectifier is supplied with 25 volts full scale thereby
minimizing effect of diode drop variation with temperature The 25 volts is then
scaled down to 5 volts for control and telemetry
This circuit wil hold substantially constant current into a shortshy
circuited load Fortunately the exponential character of the output wave-form
due to finite saturated inductance in mag-amp and leakage inductance in
transformer resdlts in a diminishing peak output voltage for small firing
angles and corresponding limited peak current into a short This is of
course desirable to-prevent excessive current in inverter
As noted above the modulation of the vaporizer and neutralizer heater
supplies is similar to that of the magnet however with differences in current
sensing
For the vaporizer and neutralizer heater supplies two (2) modes of
control are required 1) constant RMS current and 2) 100 control from on
to off when under control of engine loops
16
For RMS regulation an RMS aproximation circuit was chosen as more
reliable than thermal sensing - This consists essentially of a hybrid peak
average filter on the rectified output of the current transformer (An averaging
filter will indicate acurrent less than the RMS value a peak filter will
indicate a current greater than the RMS value) Since the line regulator qill
hold the input square-wave voltage constant to the magnetic modulator the
latter must only regulate for load changes including however a shorted
output
3 Cathode RMS- Current Regulator
See Drawing No X3188113 for schematic As indicated above in the discussion
of single inverter modulation the cathode supply uses a pulse-width modulated
driven inverter The output of this inverter therefore will with a line
voltage varying from 40 to 80 volts be required to vary from nearly full on
pulse-width to a narrow pulse width with the peak voltage varying 2 to 1
With the large step-down from line voltage to 5 volts at 40 amps to the
load ahd the need for a remote transformer at the thruster to avoid excessive
linedrops the transfoenar leakage inductance for the combined inverter autoshy
transformer and remote transformer results in a significantly inductive load
This -inductive load will therefore result in a current waveform which is
exponential with a time constant significant relative to the half-period It
is this waveform then which must be modulated to maintain constant RMS
current as the line voltage varies
The detection circuit chosen for EMS control is an approximation circuit
rather than atrue RIS thermal sensing circuit since it offers higher
reliability greater independenceof ambient temperature andfaster response
(the latter is an important consideration in engine loop stability)
Referring to schematic drawing no X3188113 the network which provides the
RMS approximation detector consists of the dual series R-C shunts across the
current transformer T6 in combination with hybrid peak-average rectifier-filter
CR19 CR20 RIO and C13
The output of the circuit shown closely tracks the desired function relating
RMS current value to peak current value as a function of pulse width Fig 3-1
is a plot of-the analytical value of the desired functions
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As the line voltage increases from 40 to 80 volts the inverter peak
output voltage and peak current increases proportionately for a given load
For a constant RMS value the pulse-width required will decrease and this
decrease will be forced by the feedback to the pulse-width modulator
As the pul-se-width narrows the degree of shunting contributed by the currentshy
transformer RC shunt loads will increase reducing the voltage across the
transformer secondary Thus the rate-of-change of detection output as a
function of pulse-width may be chosen to closely fit the desired function
Tests of this network at 25 amps and 40 amps load have verified a regulation
accuracy of 1 between 40 and 80 volt line Similarly short circuit current
is held to within 2 of regulated nominal
Current telemetry for this circuit is derived from the detector emittershy
follower in parallel with the current feedback Isolation resistors in telemetry
circuit permit shorting of telemetry without shifting controlled current more
than 1
Three modes of operation are required of this circuit I) regulated at
40 amps in a preheat condition 2) regulated at 25 amps in a preheatshy
standby condition and 3) controlled between 10 and 40 amps as a function of arc current ie when arc current exceeds a set-point value cathode
current will be cut back rapidly from 40 amps to 10 amps or less Hencej in
normal engine-loop operation the cathode current will stabilize at some value
between 40 amps and 10 amps such as to maintain the desired arc current
The control for the above indicated functions is derived from a function
generator located in the control module described elsewhere This control
is shown as an input signal command reference on schematic X3188113 The
circuit is mechanized to provide 40 amps with 0 volts command and cut-off at
+5 volts
The basic inverter circuit drawing X3188113 has been described under
paragraph 2 (b) above Single Inverter Modulation
4 DC Voltage Regulation
a Arc Supply
See Drawing X3188109 and Drawing X3188117 for schematics of this
circuit
This circuit uses the pulsezwidth modulated inverter discussed above
As in the cathode circuit discussed above the arc circuit uses an
operate and standby inverter with a aonmon output transformer
The arc supply must provide a starting boost of 150 volts at
no load dropping to 36 volts at 20 ma and regulated at 36 volts for line
and load up to 7 amps Also the supply is to be tripped off for overloads
in V4 (arc) V5 (screen) or V6 (accelerator) Telemetry is required for
both current and voltage with high calibration accuracy telemetry for current
between 2 and 7 amps and voltage between 34 and 36 volts
The supply is floating at the screen potential of +2 KV
in Drawing X3188117 the starting boost is provided through currentshy
limiting reactor Ll to rectifier CR4 When load increases to 20 ma voltage
from boost circuit will drop below 36 volts and load current will be drawn
from main rectifier CRI CR2 through filter L2 Cl
In Drawing X3188109 voltage telemetry and feedback are derived from
output transformer through CR19 CR20 and associated averaging filter since
average AC voltage is linear proportional to DC output voltage except for
load regulation in rectifier and filter The latter is compensated by load
current feedback sunned with voltage feedback Change in output due to
temperature change in rectifier and choke will not be compensated but should be
less than for 500C variation This technique is less complex than a
mag-amp voltage sensor or Hall effect voltage sensor and is expected to be
as accurate
In Drawing X3188117 current sensing is obtained with current transshy
former TI located in load secondary There will be a lack of linear cbrrelashy
tion between AC current and DC load current due to pulse-width modulation
Assuming perfect transformation and perfect square-waves a linear correlation
would exist between DC current and peak AC current For exponential wave
forms however this is not true A quasi-peak detector filter gives adequate
correlation
Two (2) rectifier-filter circuits are shown with T1 transformer These
are necessary to provide positive telemetry and negative current feedback
the latter necessary for compensation summing with positive voltage feedback
20
b Accelerator Supply
See Drawings X3188125 X3188107 and X3188115 for schematics of this
supply
This circuit will use a driven square-wave inverter
Regulation will be obtained by controlling the DC voltage input to
the inverter By this technique transformer will put out square waves
requiring only capacitor filtering for switching period and minimizing voltage
ringing which is high with a low-pass filter on output
The line regulator used here is identical with that described above
for the 5 KHz system with feedback from accelerator output instead of
from line regulator output
The accelerator supply uses one operating inverter and one standby
inverter with DC outputs from transformer rectifier in series thus providing
a redundant transformer rectifier
A winding on the output transformer of the operating inverter senses
failure of this inverter The control module on sensing failure will
switch the standby inverter on by applying a gating ON signal to the 946
gates in the inverter base circuit while removing the gating signal from
the 946 gate of the operating inverter
Referring to Drawing X3188115 output of accelerator inverter
rectifier is filtered with low-pass filter Ll Cl Choke Ll also provides
arc suppression Bleeder resister Rl R2 R3 provides voltage and current
sense for regulation telemetry and overload trip
c Screen System
See DrawingsX3188131 System Block Diagram X3188105Screen Inverter
Schematic andX3188115 High Voltage Filter Schematic
The screen system uses eight pulse-width modulated inverters phased
18 of a half-cycle apart with rectified outputs in series feeding a cormmon
L-C low-pass filter Frequency of inverters is 125 KHz resulting in a
ripple frequency of 200 KHz with a peak-to-peak unfiltered ripple of 500 volts
maximum at high line
21
With the relatively high frequency ripple the size and weight of the
output filter is small for the-high power out (2 kilowatts) A ferrite
cup-core choke (42 mm diameter) is sufficient weighing only 180 grams The
output capacitor is a small (005 mfd) mica type chosen for small sze and
tolerance of high frequency ripple
The output filter is important in its contribution to high-voltage
arc suppression Since the output capacitor may be relatively small for
ripple suppression the intensity of arc drawn from the capacitor is
significantly less than that from the larger capacitor which would be required
with a low-frequency ripple
The output filter choke is also sized to provide arc suppression by
limiting the-current which may be drawn from the inverters before overload
trip shuts the inverters down
The staggered phase technique has a further advantage relative to the
size of the output filter choke This is the relatively low peak ripple
unfiltered ie 250 volts Thus at no load or very light load where
choke is no longer critical permitting output voltage to peak the maximum
rise in output voltage due to peaking will be 250 volts during a step-load
transient before the closed-loop pulse modulation can reduce the pulse-width
and drop the voltage
Referring to Drawing X318811 high voltage filter schematic output
voltage of the screen system is sensed with a tapped bleeder resistor
providing both voltage feedback for regulation and votage telemetry at 5
volts full scale (telemetry is isolated in control module)
Current is sensed with a resistor in the return to provide an overcurrent
trip in the control module where isolation amplification and inversion is also
provided for telemetry
The technique of pulse-width modulation for regulating output voltage
has been described before under discussions of single inverter modulation
and staggered phase modulation
22
5 System Control Techniques
a General
See Drawing X3188121-l Control Module Block Diagram Control
system accepts both high level digital command pulses and a low level analog
command processes and stores the commands and controls all functions of the
power conditioner The six input commands are listed below
1 On I - turns on power to heaters to warm power conditioner
2 On LI - turns on Group I power supplies and starts the cathode
preheat sequence
3 On III - turns on Group II power supplies
4 Off I - turns off the vaporizer supply
5 Off II - turns off power conditioner heaters and all supplies
Resets all memory prior to application of power to input bus
6 IBref - Used as reference in controlling the vaporizer and as
an input to the function generator to produce a reference for controlling
the cathode
The command pulses are 20 ms or greater in duration and are zero
volts when not present transitioning to 20 to 31 VDC during the pulse period
The analog control voltage is a zero to +5 volt signal capable of driving a
10 k ohm load
The control module functions are itemized below
1 Command memory
2 Overload trip and recycling
A Slow turn on
B Magnet delay
3 Standby switching
A Arc
B Cathode
C Accelerator
23
4 Function generation
5 Control amplifiers
A Cathode
B Vaporizer
C Neutralizer heater
6 Preheat sequencing
b Command Controls
Command Interface Circuit (See Figure 5-1)
All relays are initialized by a pulse command at the Off II
input When a On I command is received Ki is set which closes the circ-
to a PC preheat switch The relay contacts are not heavy enough to carry
the heater current KI is reset by applying an Off II command An On I-I
command sets K2 and also pulses the reset on the one minute timer which
initializes the sequencer and the one minute timer The line regulator is
turned on which supplies power to the 5KHz inverter which in turn supplies
power to the Group I supplies The power for the timer and sequencer comes
from the inverter and is expected to be available before the end of the On II
command The On III command sets K3 which allows the Group II supplies to
come on and switches the cathode supply set point to 40A so that the cathode
amplifier can control over the 10 to 40 A range The Off I command resets
K4 which supplies a bias to the vaporizer controller reducing the vaporizer
current to near zero
One Minute Timer (See Figure 5-2)
The one minute timer is used to control the timing of the preheat
sequence and the sampling period of the overload trip counter The timer is
mechanized using a unijunction oscillator operating at 267 Hz which is
counted down using a monolithic 4 bit counter and shaped using a monostable
multivibrator The output is a short pulse once per minute
Preheat Sequencer (See Figure 5-3)
The preheat sequencer utilizes a monolithic four bit ripple counter
for timing the 13 minute preheat sequence Zl-A allows the one minute pulses
to clock Z3 until 13 pulses have occurred The flip-flop consisting of Z2-B
24
and ZI-C is initially set so that the output to the cathode controller is at
+5 volts (Z2-B at +5v) After 10 minutes the inputs to ZI-B are true and
the flip-flop changes state allowing the cathode current to go to 40A Three
minutes later the flip-flop is reset by Z2-A and the cathode current is reshy
turned to 25A When the input from K3 is grounded the output drops to zero
allowing the cathode current to rise to 40A
c Overload Trips
Overload Trip and Integration (See Figure 5-4)
The trip and integration circuit detects and counts overloads
provides a telemetry signal which represents the total number of overloads
at any moment and detects a solar panel undervoltage When an overload
occurs Z1 is triggered which clocks the overload counter and starts the
trip sequence through Z3-A As the total number of trips increase the output
of Z8 steps in a positive direction until either a once-per-minute reset pulse
occurs 12 overloads are counted or the solar panel bus drops below 36 volts
at which time the power conditioner is shutdown The ripple counter consisting
of Z4 through 7 will probably be replaced by an MC939 for convenience of
packaging and reliability
Trip Timing Circuit (See Figure 5-5)
The trip timing circuit times the off period of the Group II
spplies The circuit consists of two monostable multivibrators constructed
of discrete components due to the long time constants required The overload
trip and integration circuit triggers the first one-shot which gates off all
Group II supplies and the magnet At the end of the trip period the second
one-shot is triggered and the Group II supplies are turned back on The
magnet supply is turned on at the end of the second one-shot pulse which
lasts one second
Trip Shutdown Circuit (See Figure 5-6)
The trip shutdown circuit provides slow turn-on for the accelerashy
tor Arc and Screen supplies to prevent high voltage rate of change and proshy
vides buffering between the supplies and the control module When the trip
occurs Ql turns on turning Q2 on which turns Q3 and Q4 on clamping the
output to zero At the end of the trip) Cl charges up slowly causing the
output to rise slowly The output is used as the reference supply for the
Arc Screen and Accelerator supplies The vaporizer is shut off by applying
25
a turn-off bias to the input through CR9 Q5 keeps the magnet off by
pulling current through the turn-off winding of the mag-amp The input
fromrelay K3 is released from ground at an on III command allowing
the vaporizer accelerator arc and screen supplies to come on
d Analog Controls
Analog Control Amplifiers (See Figures 5-7 5-8 5-9)
The system consists of three major control loops each of which will
be discussed separately
Neutralizer Heater - Neutralizer Keeper
This control function requires the neutralizer heater current to be
reduced from the preheat level of 28 amps to zero when the neutralizer
keeper voltage drops two volts below a preselected reference The current
reduction is to begin from the point at which the NK voltage equals the
present reference Under present requirements this level is between 10 and
20 volts The NK supply rides on a bias of up to + 30 volts A differential
amplifier is used to sense the voltage difference The amplifier will be
scaled so that a NK voltage of 0 - 30 volts will be 0 to 5 volts at the
amplifier output
The controller requires a zero to 5 volt signal to control the outshy
put current from full on to off An intermediate amplifier is mechanized
which provides the function below
Enhc = 15 2Enhref - inks -Fi Ench 0
Enhc=O0 2Enhref - Enks
Where
Enhc is neutralizer heater control voltage
Enref is the reference voltage
Enks is the scaled neutralizer keeper voltage
53 is a bias used to allow Enhref to be a zero to 5 volt signal
The neutralizer heater control amplifier schematic includes a bias
supply consisting bf a temperature compensated zener diode This reference
is used in the other two amplifiers The diode at the output of the amplishy
fier is to keep the output from going negative
26
Vaporizer
The vaporizer is controlled by comparing a screen current reference
voltage to the voltage scaler representing screen current As the screen
current exceeds the preset reference level by 10 ma the vaporizer is proshy
portionally reduced from 12 amps to less than 05 amps Since the screen
current is scaled 5 volts per ampere and the reference is 0 to 5 volts for
05 to 1 ampere and the vaporizer control requires a zero to 5 volt signal
to reduce the output from 12 amps to near zero an amplifier is required
that mechanizes the following function
Evapc = -200 [Esr - Ess + 25] Evapc 0
Evapc = 0 jjsr - Ess + 25 1lt 0
Where Evapc is the vaporizer control voltage
Ear is the screen reference voltage
Ess is the screen current scales
The vaporizer control amplifier schematic shows the amplifier designed
to perform the required function To accomplish the required gain the input
resistor was of necessity less than 10ko To prevent loading of the IBref
source a voltage follower will be implemented
Cathode Heater
The cathode heater is controlled by the arc current If the arc
current exceeds a reference by 01 amperes the cathode current is cut back
proportionally from 40 to 10 amperes The reference is a 0 - 5 volt signal
from function generator The arc current is scaled at 5 volts for 8 amperes
The cathode controller requires a zero to 5 volt signal to reduce the outshy
put current from 40 to 10 amperes To accomplish the required control
function an amplifier is mechanized which provides the function given below
Eco - 80 Eas - 125 -5 Earef 1 Ecc - 0
E Earef - 125 -5 Ealtr 0Ecc + 0 Eas
8 lt Where
Ecc is the cathode controller control voltage
Eas is the scaled arc current
Earef is the reference voltage
Function Generator
The function generator converts the Beam reference to an Arc reference
following a curve provided by JPL The curve is approximated by three
27
straight lines The amplifier Fijure 5-10 consisting of Zl QI Q2 and
Q3 provides dc biasing and sufficient dynamic range to provide drive to
the breakpoint network consisting of R6 RIO R14 R20 CR1 and CR2
Amplifier Z2 corrects for amplifications factor
The breakpoint network utilizes temperature compensated diodes to
provide the required switching points The diode specification gives a
temperature coefficient at one current only At lower currents the coefficient
is higher but not significant enough to effect the required performance
The current levels through the network are selecped high enough to pass
the critical knee area quickly At the knee the zener contributions is not
significant and the knee softness causes rounding of the curve at the breakshy
point Freon freeze tests showed that no significant shift occurred in the
curve occurred for variations in temperature A curve showing the output vs
input voltage is attached The circled dots are the breakpoints and end
points required to match the actual curve
e Standby Controls - See Figure 5-11
Cathode Standby Control - See Figure 5-11
The cathode standby control circuit operates exactly as does the
Arc circuit of the Accelerator Arc standby control circuit explained below
The sense signal ts either zero volts for off or minus 5 volts for on sense
Accelerator amp Arc Standby Control - See Figure 5-12
The Accelerator and Arc standby control circuit delays the On III
command -approximately 01 seconds and turns on the standby module if the
primary module is inoperative Transistor 01 discharges and releases C2 at
the end of the On III command C2 charges to a voltage equal to VR2 and
the base to emitter drops of Q2 and Q3 at which time ZI-A output goes high
If the accelerator primary on sense is not present the Accelerator standby
drive is turned on and the Accelerator primary drive is turned off If the
Arc on sense is present when ZI-A goes high Z2-B is inhibited and Q5 cannot
turn on If however Zl-A goes high when the Arc sense is not present Z2-B
output goes low turning Q5 on and inhibiting the Z2-A gate
28
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6 Test Data
Presented herewith are test results taken on preliminary breadboards
of key circuits of the system together with data on critical components
Some subsystems such as Screen Supply require the assembly of a number
of modular circuits which have not yet been built hence cannot be
reported on at this time
a tow Voltage Group
Data is presented on the Vaporizer Neutralizer Heater
Neutralizer Keeper and Magnet Supplies showing 1) regulations vs
load (line regulation is performed by line regulator) 2) telemetry
output vs load current and 3) controlled current vs control voltage
b Modulated Power Inverter
Data-is presented on losses measured in principal elements
of a 300 watt screen inverter
c Cathode Heater Supply
Data is presented on load current regulation vs line voltage
variation for 3 values of load current
d Function Generator
Aiplot of measured output-is given for arc current reference
as a function-of commanded screen current reference
e Components
Data is given on switching speeds of power transistor used
in inverters also on PIV of screen high voltage recterfier bridge
f Analog Control Circuits
Data presented shows the roll-off characteristics of the
operational amplifiers for
1) Cathode Current vs Arc Control
2) Vaporizer Current vs Screens Control
3) Neutralizer Heater Current vs Neutralizer Keeper Control
41
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Screen drive inverter circuit with 16 MR inductor and a 005pf
5000 VDG capacitor in output filter
a Power Loss in Power Transistor
Line 80 VC
Pulse width 25ps
Power output 300 W
Room temperature 820F
Power transistor beat sink temperature 1220F
AT 400F
610F rise = 1 watt
40OF 2 61 = 645 watts loss in power transistor
Drive transformer voltage 35
Drive transformer average current 70 ma
Power for drive circuit - 70 ma x 35 v = 246 w
Base drive current 125 A pulse width 24 is
VBE IV
Power VBE = 251s40ps x 125A x 1lV = 086W
Corrected power transistor power loss equals 645W - 086W 559W
b Line Voltage 40VDC
Pulse width 36ps
Power output 300 W
Room temperature 850F
Heat Sink temperature 136F
T - 51OF
Power in loss in power transistor = 511 4 6-1 835 W
Power in drive = 35 V x 115 ma = 4 W
Power loss in base = 125A x I1V x 3540 P 120 W
Corrected power loss in power transistors = 835 W - 120 W = 715 W
c Summary of Transistor and Drive Loss
High tine Transistor loss in power 559 W 80 VDC Drive Power 246 W
Total 805 Watts loss
Low Line Transistor Power Loss 715 W 40 VDC Drive Power 400 W
Total 1115 Watts loss
d Output Transformer Loss
At 80V line 50 percent duty cycle output 300 V DC at 3A measured
loss (calorimeter) = 385 Watts
54
Cathode Heater Regulation
(RMS Regulator)
Line Voltage
40
45
50
55
60
65
70
75
80
lOA Load
100
100
101
100
100
100
100
100
100
25A 40A
250 401
251 402
251 402
251 403
252 404
251 404
251 405
251 404
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Solitron SDT 325VI01 Transistors Salitron SDT 8805 Transistors
Collector Current = 7A Collector Current = 7A
Serial Serial No On Off No On Off
31 8 7 x 10-6sec 1 2 12 x 10- 6sec
32 1 10 2 18 10
33 1 10 3 22 15
34 9 9 4 20 15
35 8 8 5 25 10
36 9 7 6 25 10
37 9 9 7 20 10
38 10 7 8 20 10
39 11 7 9 22 08
40 11 8 10 25 10
41 11 8 11 30 14
42 11 8 12 20 10
43 10 9 13 25 15
44 10 8 14 17 10
45 10 8 15 20 10
46 11 9 16 25 15
47 10 29 17 22 12
48 10 7 18 25 10
49 11 9 19 22 10
2-1 10 8 20 30 15
2-2 12 8 21 30 15
2-3 11 8 22 20 15
2-4 11 9 23 15 15
24 10 10
25 25 10
26 20 08
27 20 10
28 15 08
29 15 06
30 15 06
57
High Voltage Rectifier - PIV
Semtech SA 2258 Diode Bridges (Rated 2A 750V)
P19 l0p A RY RY BY BY
Serial No cw ccw cw ccw
1 1040 1000 1120 1160
2 1240 1040 1080 1080
3 1140 1040 1020 1200
4 1240 1100 1180 1150
5 1100 1140 1080 1200
6 1140 1180 1120 1240
7 1160 1120 1160 1240
8 1120- 990 1160 1080
9 1080 1240 1140 1080
10 1160 1240 1200 1180
11 1000 1120 1180 1200
12 i000 1060 1120 1100
13 1030 1180 1000 1100
14 1210 1040 1080 1080
15 1080 1260 1300 1180
16 1220 1180 1220 1140
17 1220 1140 1260 1160
18 1140 1180 1060 1140
19 1130 1140 1120 1126
20 1040 1000 1000 1060
21 1220 1200 1180 1100
22 1100 1140 1200 1120
23 980 1160 1060 1240
24 1100 1080 1110 1220
25 1100 1110 980 1120
26 1180 1060 1120 1220
27 1060 1040 1140 1100
28 1120 1080 1200 1190
29 1190 1280 1060 1140
30 1160 1000 1040 1180
31 1040 1240 1240 1120
32 1180 1160 1080 1160
33 1100 1100 1160 1020
34 1160 1040 1160 1040
35 1000 960 1080 1200
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7 EFPICIENCY ANALYSIS
a Screce InverterNodule
Worst Case 300 watts out (2100 watts seven inverters)( qorst case = 7 inverters on normal = eight inverters on)
At 40-Volt line
1) Transistor saturated loss Assume 93 percent effici6ncy 95 percent duty cycle
I 300 = 87 amperes peak = 87 x 095- 83 ampere average
093 x 39 x 095
Psat IcVce sat 83 x 07 - 58 watts (two transistors)
2) Transistor switching loss Assume partially inductive load Assume is = 05 microsecond f = 125 KH3
P 29 E I t f per transistor sw mces p
= 49 E I t f for two transistors
-x 78 x 87 x 05 x 10 6 x 125 x 103 = 419
= 190 watts (two trensistors)
3) Psat + P = 58 + 19 = 77 watts (excluding base loss)
4) Base drive loss (including modulator) (circuit P = 9)
-PBD 20 volts x 10 = 200 watts + 10 watt in modulator (estimated)
30 watts
5) Line capacitor loss (foil tantalum)
P C 041 watts ceest
6) Transformer loss (from design data)
PT = 5 watts (20 w core loss 30 w copper loss)
7) Output rectifier loss (manufacturers date)
4 diodes OSV dropdiode lOA = 32 watts
GE Bulletin 121EC for two 175 microfarad200 volts page 9
6
8) Total inverter loss at 40-volt line
Transistors 77 (65 w measured)
Bdse drive 30 (33 w measured)
Line capacitor 04
Transformer 50
Rectifiers 32
Total 193 watts
9) Input power 300 + 193 -3193
L0) Efficiency = 300 = 940 percent 3193
At 8O-VQlt Line
1) Transistor saturated loss (transistor on half time)
Psat = 83 x 07 = 279 watts (two transistors)sat 2
2) Transistor switching loss
P = 49 x 156 x 87 x 05 x 10-6 x 125 x 103 sw
= 380 watts (two transistors)
3) Psat + Psw 290 + 380 = 687 watts
4) rbase drive = 300 watts (on half time) - 150 WaLL 2
5) Line cap PC 093 watts
6) Transformer loss Pcore loss= 200 watts (from design data)
p 30 x 05 = 15 W cop loss
- (same current as 40-volt line on half time PW)
GE Bulletin 121EC page 9
PT = 20 - 15 =-35 watts
7) Output rectifier loss PR = 32watts = 16 watts (on 12 time-same current as volume) 2
8) Total inverter loss at 80-volt line
Transistors 670 (575 w measured)
Base drive 150
Line capacitor 093
Transformer 350 (385 w measured)
Rectifiers 160
Total 1423 watts
9) Input power = 300 + 1423 = 31423
10) Efficiency = 300 = 952 percent 31423
Nprmal Case 8 inverters on 2100 w =262 watts out 8
At40-VolE Line (Duty Cycle = 95 x 78 - 083)
1) Transistor saturated loss
I = 262 = 87 amps peak093 x 30 x 083 - = 87 x 083 x 72 ampsaver
Psat 72 x 07 = 504 w
2) Transistor switching loss
-6P = 49 x 78 x 87 x 05 x 10 x 125 x 103
= 190 watts (2 transistors)
P3) Psat + sw = 504 + 190 694 w
4) Base Drive Loss
PBD - 30 x 083 = 262 w 095
64
5) Line Capacitor Loss = 041 x (76)2 = 031 W(971
6) Transformer Loss
Core Loss a B m 3E
w
PCoM 20 x (78)3 = 134 w
Copper Loss cy Duty Cycle
P 30 x 083 = 262 w wp 095
P = 134 + 262 = 396 w
7) Output Rectifier Loss
a Duty Cycle
Pr = 32 x 083 = 28 w 095
8) Total Inverter Loss at 40V line
Transistors 694 BAse Drive 262 Line Capacitor 031 Transformer 396 Rectifiers 280
1663
9) Efficiency = 250 94 2666
At 80-Volt Line (Duty Cycle - 083 = 042) 2
1) Transistor saturated loss
Ic av = 72 = 36 2
Psat = 36 x 07 =252 w
2) Transistor switching loss
Ic peak same as 40 V line voltage = 2x
Psw = 190 x 2 = 380 w
3) Psat + Paw = 252 + 380 = 632 w
4) PBD = 262 x 12 = 131 w
2 5) PLine capac = 093 x 76 = 071 w
87
6) Transformer Loss
Pcore = 134 w (same as 40V line)
Pcopper = 262 x 12 = 131 w (same current 12 time)
PT = 134 + 131 = 265 w
7) Output rectifier loss
Pr = 28 x 12 = 14 w (same drop 12 time)
8) Total inverter loss at 80V line
Transistors 632 Base drive 131 Line capacity 071 Transformer 265 Rectifier 140
1239 w
9) Efficiency = 250 = 951
2624
b Arc Inverter Module
1 operate 1 standby Po = 36V x 7A = 252W
Scaling losses from screen inverter
At 40 Volt Line
1) Transistors 252 x 694 = 668 26-2
2) Base Drive = 252 x 262 = 252 262
3) Line Capacity = 252 x 031 = 030
4) Transformer = 252 x 396 = 382
5) Total Inverter Losses 1332 w
6) Effici ency = 252 = 950 2653
45-7-CC-Et REV 3-61 66
At 80 V Line
1) Transistors = 252 x 632 = 610 2
2) Base Drive 252 x 131 = 126262
3) Line Capaci-ty = 252 x 071 069 262
4) Transformer = 252 x 265 255 i62
5) Total Inverter Losses =1060 W
6) Efficiency = 252 =966 2606
c Accelerator Inverter Nodule
1 operate 1 standby inverter POT = 200 W transient
(2000 V 01A transient)
(2000 V 001A steady state) Pos s = 20 W steady state
This inverter operates at duty cycle of 100 with a regulated input line of 35 volts
Ic = 200 = 632 A peak = 632 A aver 93 i 34
1) Transistor Loss
=Psat 632 x 07 = 44 W -Psw = 49 x 68 x 632 x 05 x 10 6x 125 x 103 r 12 W
PT = 44+ 12 = 56 w
2) Base Drive Loss
PBD = 2Vx 08A = 16W
3) Line capac loss = negligible (Ion ripple)
4) Transformer loss = 200 x 336 = 302 W -R2
5) Rectifiers (10 diodes in series)
PR = 01A x 08V x ID = 08 W
6) total Inverter Loss (transient)
Transistors 56 Base Drive 16 Transformer 30 Rectifiers 08
Total 110 W
B - Steady State
Ic 632 x 110 = 062 A peak = average
1) Transistor Loss = 56 x 110 = 056
2y BaseDrive Loss
3) Transformer
Pcore x 12 total of transient loss = 302 = 15 2 -2
P = 161 x i = negligiblecopper 10
T = 151
4) Rectifiers Loss = 08 x 110 = 08 W
5) Total inverter loss
Transistors 056 Base Drive 160 Transformer 151
Rectifiers 08 Total 375 W
d Cathode Inverter Module
= operate 1 standby inverter PQ 5V x 40A 200 W
40V Line (95 duty cycle)
I = 200 = 58A peak93 x 39 x 95
= 58 x 95 = 55A aver
1) Thansistor Loss
Psat = 55 x 07 = 375 W
P = 49 x 78 x 58 x 05 x 10-6 x 5 x 103 05Wsw
PTot = 375 + 05 = 425 W
2) Base Drive Loss
4WPBO = 2V x 07A = shy
68 6657-CC-E REV 3-61
3) LineCapac Loss = 025W (from G- E Bulletin 121 EC)
4) Transformer Loss = 200 W x 02 4 watts (98 effic)
5) TotalInverter Loss
Transistors 425 Base Drive 140 Line Capacitor 025 Transformer 400
Total 990W
80 V Line
1) Transistor Loss
Psat = 55 x 07 = 187W 2
P = 05 x 2 = 100W Sw
PTot = 187 + 100 = 287W
2) Base Drive Loss
PBO 2 x07 x 12 = 07W
3) Line Capac Loss e 080 W (G E Bulletin 121 EC)
4) Transformer Loss
Since this is currentregulator same current as at 40V For same RMS voltage average voltage will be lower but assume same
same core loss
PT = 400W (same as 40V)
5) Total Inverter Loss
Transistors 287 Base Drive 070 Line Capacity 080 Transformer 400 Total 637 W
69
447-CC-EN PEV -61
e 5 KHz Inverter Module
I Operate 1 Standby Inverter
Supplies Magnet Vaporizer Neutralizer Heater Neutralizer Keeper
+ 12V + 5V
Po = 20 + 20 + 41 + 21 + 15 + 15 = 105 W
This Inverter is supplied from Line Regulator at 35V out (constant)
1 105 = 332 A peak = average93 x 34
1) Transistor Loss
Psat = 332 x 07 = 232 W 4 6=
Psw = -x 68 x 332 x 05 x 16-6 x 5 x 103 025 W9
Pt = 232 + 025 = 257 W
2) Basj Drive Loss
Pbd = 2 x 05 = 10 W
3) Line Capac Loss = negligible (low ripple)
4) Transformer Loss
98 Effic Pt = 105 x 02 = 21 W
5) Total Inverter Loss
Transistors 257
Base Drive 100
Transformer 210
TOTAL 567 w
f 5 K-z Line Regulator
This Regulator supplies power at 35V to 5 KHz Inverter and to all Pm
Inverters (10)
Po = 105 + 10 x 30 = 105 + 30 = 135 W
70 pound87-CC--EN REV 3-81
At 40V Line
Ic = 135 = 386 A peak35 shy
= 386 x 95 = 366 A
1) Power Transistor Loss
Psat = 366 x 07 = 256 W
46 3 -Psw 104 Hz = - x 78 x 386 x 05 x 10 x 10 x 10 = 063
Pt = 256 + 063 = 319 32 W
2) Choke Loss (Design Loss) = 02 x 135 = 27 W
3) Output Capac Loss (est) = 05 W
4) Line Capac Loss (est) = 05 W
5) Power Transistor Drive Loss (est) = 10 W
6) Pt = 32 + 27 + 05 + 05 + 10 = 79 W
At 80V Line
1) Power Transistor Loss (On 12 Time)
Psat = 256 = 128 - 2
Psw = 063x 2 = 126 W (same current)
Pt = 128 + 126 = 254 w (2 x voltage)
2) Choke Loss (same current) = 27 W
3) Output Capac Loss est = 10 W
4) Line Capac Loss est = 10 W
5) Drive Loss est = 10 W
6) Pt = 830 W (measured loss = 82 W)
71
g Accelerator Line Reulator (35 V out)
40 V Line
A Transient
Po-= 211 Watts
211Ic = 602 A peak =602 x 95= 575 A
1) Transistor Loss
Psat = 575 x 07 = 403 W
Psw = x 78 x 602 x 05 x 106 x 10 x 10= 104 W 9
Pt = 403+ 104 = 507 W
2) Choke Lobs (Design Loss) 02 x 200 = 40 W
3) Output Capac Loss (est) = 07 W
4) Line CapacLoss (est) = 07 W
5) Drive Loss (est) = 15 W
6) Total Loss = 507 + 40 +07 + 07 + 15 = 1197 W
B Steady State
Po = 211 W
1) Transistor Loss-= 307 x 01 = 051 W
2) Choke Loss = 40 x 01 = 004
3) Output Capac Loss (est) = 00
4) Line Capac Loss (est) = 00
5) Drive Loss (est) = 15
6) Total Loss = 205 W
7-CC-W RrY 3-61 72 85
--
80V Line
A Transient B Steady State
1) Transistor Loss
Psat = 403 = 202 W
Psw = 104 x 2 = 208 W
Pt = 410 w 041
2) Choke Loss (design) = 40 W =- 004
3) Output Capac Loss (est) = 15 W = 000
4) Line Capac Loss (est) = 15 W = 000
5) Drive Loss (est) = 15 W = 150
6) Total Loss =125 W = 195 W
h Arc Rectifier Fitter
40V80V Line same since current remains same except divides between Main Rectifiers and Commutating Rectifier
1) Rectifier Loss = 08 x 70 = 56 w (3)
2) Choke Loss (design) = 252 x 01 = 25 W
3) Output Capac Loss (est) = 20 W
4) Total Loss =101 W
i HV Filter
Same at 40V and 80V Line
1) Screen Bleeder = 2000V x 001 A = 2 W
2) Aceel Bleeder = 2000V x 001 A = 2 W
3) Screen Current Sens-e Resistor = I W x 1 A I W
4) Accel Current Sense Resistor = 5V x 01A = 05 W
5) Screen Choke (design) = 20 W
6) Accel Choke (design) 05 W
7) TOTAL (73) = 80
j Maanetic Modulator
At 40-volt line amp SOV line (regulated by 5 KHz Line Regulator)
1) Vaporizer
=Pout 20 Watts
Ptransformer = 02 x 20 = 040
P 02 x 20 = 040 mag-amp
Pdiodes 20 x 10 =025 O
2) Neutralizer Heater
Pout 41 Watts
PNH = 41 x 105 c-21 Watts
) Neutralizer Keeper
VAou t 180
a) Ptransformer = 18098 = 184 = 04 Watt
b) Pchoke - 1899 - 18 -- 02 watt
c) Prectifiers 05 ampere x 16 volts = 08 Watt
d) PT i 0O4 + 02 + 08 = 14 Watt
4) Magnet
=Pout 20 Watts Iout = 085 amperes
a) Prectifier = 085 x 10 = 085 Watts
b) Ptransformer = 20098 - 20 = 040 Watt
P) P 040 Wattmag-amp
d) Ptotal i165 Watts
5) Ptotal at 40-volt line magnetic regulators
PT = 105 + 21 + 14 + 165 = 480 Watts
746657-CC- EN REV 3 -61
k Sunmary of Losses
Losses
Module 40V Line 80V Line
1 Screen inverter - Worst Case - 71NV x (193W) (1423W)
Normal Case- 81NV x 166W 1239W
133W 1060W2 Arc Inverter shy
3 Accel Inverter - Transient 110W 110W
Normal 375W 375W
4 Cathode Inverter 990W 637W
567W 567W5 6K 3 Inverter
6 5KH3 Line Regulator 79W 83W
7 Accel Line Regulator - Transient (1197W) (125W)
Normal 205W 195W
101W 101W8 Arc Rectifier - Filter
9 High-Voltage Filter 80W 80W
10 Magnetic Modulator 48W 48W
50W 50WI1 Control Module
75
8 RELIABILITY
8a Reliability Analysis
W Mission Reliability calculated to 09702 where R(t)= r R and
mission time is 10000 hours The reliability block diagram (Fig 8l)
displays the complete system with all involved subsystems or units The
reliab4lity for each of the units was determined by the relationship
-4t R = e except for those units where redundancy practices were followed
(for which math models are noted) The set of failure rates utilized
for the analysis effort were developed by utilization of Hughes Document
R22-100DC After determination the subsystem failure rates were then
modified by use of an E-factor the Hughes Experience factor The set
ofutilized failure rates and a rationale justifying use of these
failure rates together with the E-factor follow The resultant failure
rate (k) of-each unit modified by the E-factor (0475) is rioted on the
applicable Parts List (see Section 8a4)
See Table 81 for listing of unit failure rates and reliability values
8al) The-Screen Inverters
For the purpose of this analysis the missien time of (10) 4
hours was broken into three intervals
Interval Time Hours
1 0 to 2500
2 2500 to 5000
3 5000 to 10000
At the start of flight seven (of the eight active) Inverters are
required At the end of each interval the requirement drops as
follows
76
bull92998 I 999994 I
94223
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IN V
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9522
-3 [100o
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bull99 994
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99223
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-324
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199938 A Y24
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LVlj
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-shyraM C824 9986
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t
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iszacK
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=(U-F4S 0 -cs li- SY T S14 (P6 =
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9
1p CA7XeZ dampTAAT FIJQ-W
2 25oo 6 -3 Soo
Interval Inverters Required at
End of Interval
1 7
2 6
3 5
The reliability Probability of meeting these requirements for
each interval was determined from the formula
d = R i )n-i
edund = z) (1 - R1 2) i = c 12
where n = operating inverters
c = inverters required at end of each interval
R e-lt X = failure rate
t = interval time
The redundant screen inverter reliability calculated to 09998
8a2) Transformer Short-to-Ground Failure Mode
Since the entire power conditioner will be inoperative
if one of the output transformers of the Accelerator and The
Screen Inverters fail in failure mode short to ground and
since each transformer is exposed to seven failure modes a
conservative failure rate of 5 x 10 (onefifth of the transshy
-former failure rate of 20 x 10 9 ) has been placed in series
with the other elements for each of those transformers (see
block 14 on Figure 81)
Where those transformers are part of the redundant
or standby circuitry the failure rate has been accordingly
-modified from 20x 10 9 Hrs to 15 x 10- 9 Hrs to account
for the balance of failure modes inside the redundant portion
of the circuit
78
8a3) Assumptions and Considerations
1 All parts exhibit constant failure rate
-2 Parts within a block on the logic diagram fail
independently Failure of any part in a block (except
for several redundant Operational Amplifiers in the
Control Module) causes block failure
3 All blocks on the logic diagram fail independently
4 Mission time is 10000 hours
5 Power Conditioner temperatures are 250C (base plate) and
350C (junction) except for the Control Module where the
temperatures are 200C and 250C respectively
6 Discrete semiconductors operating in digital circuits
are derated to 10-15 of their rated power stress All
other parts (in general) are derated to 30-40of their
rated stress
7 Part failure rates reflect Hughes spacecraft experience
through 31 August 1968
8- The reliability analysis predictions do not consider
wearout failure
9 The reliability mathematical models for standby
redundancy consider that the dormant failure rates are
greater than zero
79
TABLE 81
FAILURE RATES FOR POWER CONDITIONER
PART-TYPE
Diode Switching
General Purpose
Zener
Transistor Switching
General Purpose
Power
Integrated Circuits DTL
NA741
Resistor Carbon Comp (RC)
Metal Film
Power (RW)
Precision
Capacitor Ceramic etc
Tantalum
Magnetics Transformer Choke
Mag Amplifier
Relay
Connector
Fuse
-FAILURE RATE x 10 9 HRS
(932 946 948 etc)
Active Dormant 24 10
60 10
240 2shy
75 10
120 10
1206 100
140 50
840 300
10 01
22 002
65 001
39 01
60 02
260 10
200 05
300 10
1000 100
250 25
100 10
80
Ref Dwg X3188119
(Issue with approval4 pAWT COuVTS date of 9-30-68)
LINE REGULATOR - Block 1
- 9Part Type Qty X(10) Total x
Resistor Carbon Comp 10- 10 100
Metal Film 2 22 44
Power W W 1 65 65
Capacitor GlassMylar etc 5 60 300
IF Tantalum 2 260 520
Diode Switching 7 24 168
Zener 2 240 480
Transistor Power 4 1200 48000
Operational Amplifier 840
Conductor 200
Fuse 200
Connector 250
(10)- 9
x = 7967
-9 Bl ck 1 X= (475)(E X) 3784 (10)
81
Ref Dwg No X3188111 (Issue with approval date of 9-30-68)
5K HZ POWER INVERTER - Block 2
- 9 Total x (10)- 9 Quantity (10)
Part Type Active Standby Active Dormant x I X 3
Resistor Carbon Comp 6 5 10 010 60 050 50
Power W W 1 1 65 001 65 001 65
Capacitor Glass Mylar etc 1 1 60 002 60 002 60
Tantalum 6 6 260 100 1560 600 15600
Diode General Purpose 9 8 24 10 216 900 192
Transistor Power 5 4 12000 100 6000 4000 48000
Transformer 2 1 200 05 400 050 200
Relay - 2 1000 100 - 2000 2000
Integrated Circuit 3 2 140 50 420 1000 280
Fuse 2 2 100 10 200 200 200
Connector 1 - 250 - 250 - 250
9231 8703 9657
(X1) (sx2) (2x3)
Block 2 X1 = (475)(9231) = 4385(10) - 9
Block 2 X2 = (475)(8703) 413(1) - 9
B k 2 X=-(475) (9657) = 4587(10) - 9
X1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
82
Ref Dwg No X3188123 (Issue with approval date of 9-30-68)
MAGNETIC MODULATOR - Block 3
- 9- 9 Part Type Quantity (10) Total (10)
Operational Amplifier 1 840 840
Magnetic Amplifier 3 300 900
Diode Switching 33 24 792
Zener 10 240 2400
Transistor Switching 3 75 225
Capacitor Glass Mylar etc 3 60 180
Tantalum 6 260 1560
Resistor Carbon Comp 11 10 110
Metal Film 25 22 550
Power W W 4 65 260
Transforme 8 200 16D0
Inductor 2 200 400
Connector 1 250 250
- 9 Z = 10067(10)
Block 3 = (475)(10067) = 4782(10) - 9
83
CATHODE PULSE MOD amp FREQ DIV - Block A4
Ref Dwg X3188113 (Issue with approval date of 93068)
Part Type Quaptity -9
X(10) -9
Total X (10)
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp
Metal Film
4
5
10
22
40
110
Capacitor Glass Mylar etc
it Tantalum
1
3
60
260
60
780
T_= 2090 -9
(10)
SBlock A 8=(475)(2090) 993(10) - 9
84
Ref Dwg Numbers (Arc) X3188109 and (Cathode) X3188113
(Issue with approval CATHODE INVERTER AND ARC INVERTER - Block 5 date of 93068)
Part Type Quantity x (10) - Total X (10) - 9
Active Standby Active Dormant 1 22 23
Integrated Circuit 2 2 140 500 280 100 280
Transistor Switching 2 2 75 100 150 200 150
Transistor Power 2 2 1200 1000 2400 2000 2400
Diode General Purpose 18 18 60 100 108-0 1800 1080
Capacitor Glass Mylar etc 2 1 60 002 120 002 60 Tantalum 3 3 260 100 780 300 780
Resistor Carbon Comp 6 6 10 010 60 060 60
Power W W 2 2 65 001 130 002 -130
Trans former 2 2 200 050 400 100 400
Oelay - 2 1000 1000 - 2000 2000
Fuse- 2 2 100 100 200 200 200
Connector 2 250 - 250 - 250
5850 7664 7790
CE 2I) (E X2 ) (z 23)
Block 5 X1 = (475)(5850) = 2779(10)-9
Block 5 X22 = (475)(7664) = 364 (10) -
Block 4 3= (475)(7790) = 3700(10) - 9
S1 = Active Unit
X2 = Standby Unit Off
X3 = Standby Unit On
85
Ref Dwg X3188113 (Issue with approval date of 93068)
CATHODE HEATER LOOP - Block 6
-9 -9 Part Type Quantity X(I0) Total x(10)
Resistor Carbon CQmp 3 10 30
I Power W W 1 65 65
Diode Qenl Purpose 4 60 240
Transistor Switching 1 75 75
Capacitor Tantalum 2 260 520
Transformer 2 200 400
- 9 X = 1330(10)
- 9
Block 6 X = (475) (1330) = 632(10)
86
Ref Dwg X318810 (Issue with approval date of 9-30-68)
ARC PULSE MOD amp FREQ DIV - Block 7
Part Type Quantity A(10)- 9 Total (10)-9
Integrated Circuit 1 140 140
Operational Amplifier 1 840 840
Diode Genl Purpose 2 60 120
Resistor Carbon Comp 6 10 60
Metal Film 4 22 88
Capacitor Glass Mylar etc 1 60 60
I Tantalum 2 260 520
= 1828 (10) -9
Block 7 x = (475)(1828) = 868(10)-9
87
Ref dwg nos are X3188117 amp X3188109
(Both issued with approshyval dates of 93068)
ARC RECT FILTER - Block 8
Part Type Quantity ()0)-9 Total x(10) - 9
Diode Switching 7 24 168
Power 3 600 1800
Zener 2 240 480
Resistor Carbon Comp 6 10 60
Metal Film 5 22 110
Power W W 1 65 65
Transistor Switching 1 75 75
Transformer 2 200 400
Inductor- 2 200 400
Capacitor Ceramic Glass etc 4 60 240
Connector 1 250 250
- 9
X= 4048(10)
Block 8 X (475)(4048) 1923(10) - 9
88
Ref Dwg X3188 107 (Issue with approval date of 93068)
ACCEL FREQ DN - Block 9
Part Type Quantity X(10) shy 9 Total X (10)-9
Integrated Circuit 1 140 140
Diode Genl Purpose 2 60 120
ResistorCarbon Comp- 1 10 10
X = 270(10) - 9
- 9 - 128(10)(475)(270)Block 9 X =
89
Ref Dwg No X3188107 (Issue with approval date of 93068)
ACCEL INVERTER - Block 10
- 9- 9lO) Total x(10)Quantity Part Type
Active Dormant Active Dormant Active Dormant
Integrated Circuit 2 2 140 500 280 1000
Transistor Switching 2 2 75 100 150 200
Power 2 12002 1000 2400 2000
Diode Genl Purpose 8 7 60 100 480 700
Capacitor Glass Mylar etc 5 5 60 002 300 010
Tantalum 4 3 260 100 1040 300
Resistor Carbon Comp 4 4 10 010 40 040
Power W W 1 1 65 001 65 001
Transformer 2 2 150 050 300 100
Diode Assembly (10 CRs) 1 1 240 1000 240 1000
Inductor 1 1 200 050 200 050
Fuse 2 2 100 100 200 200
Connector I - 250 - 250 shy
5945 5601
(zzActive) Dorm)
Block 10 XActive = (475) (5945) = 2824(10) - 9
9 Block 10 XDorm = (475)(5601) = 266(10)
shy
Normally 200 but one of the failure modes is allocated to Block 15
90
i
Ref Dwg No X318815 (Issue with approval date of 93068)
HIGH VOLTAGE FILTER - Block 11
-Pait Type Quantity X(l0) Total X (10)
Resistor Carbon Comp 2 10 20
Power W W 2 65 130
Resistor Assy (10 Carbon 4 100 400 Comp PCs)
Capacitor Ceramic Mylar etc 4 60 240
Tantalum 1 260 260
Diode Zener 3 240 720
Inductor 2 200 400
Connector 1 250 250
= 2 2420
= 1150(10) - 9 Block 11 = (475)(2420)
91
Ref Dwg No X3188105 (Issue with approval date of 93068)
SCREEN INVERTER - Block 12
- 9Part Type Quantity x (10) Total X(I0)-9
Integrated Circdit 2 140 280
Transistor Switching
Power
2
2
75
1200
150
2400
Diode Switching 19 24 456
Diode Assembly (2-CR Pkg) 1 48 48
Capacifor Class Mylar etc
Tantalum
4
2
60
260
240
520
Transformer 3 150 450
Resistor Carbon Comp
Power W W
6
2
10
65
60
130
Fuse 1 100 100
Connector 1 250 250
SBlock 12 X = (475)(5084) 2415(10) -
x = 50844(10) - 9
Normally 200 but one of the failure modes is allocated to Block 15
92
Ref Drawing (See below)
PRELIMINARY CONTROL MODULES - Block 13
Utilized data from earlier design review
(See 2228DR 1701 Rev A pages 60 seq which lists)
= 24959 (10)- 9 The total )
- 9 - 9Thus Block 13 = (24959 )(475)(10) = 11856(10)
93
SPECIAL TRANSFORNER SEORT-TO-GROUND FAILURE MODE - Block 14
If any of the Accel or Screen Inv output transformers (a total of five) fail the entire system fails We assign a failure rate to this failure mode of a highly conservative nature 5(10) - 9 based on two factors
I) The operating voltage of the involved transformers is 2 Kv Several of the transformers have been tested in a destructive hi-pot test and insulation breakdown occurred at 15 to 17 Kv the large safety factor in the amount is indicative of HV insulation supplied
2) The total failure rate for-transformers is 20(10) 9 which rate covers all the failure modes These involve short or open in each of the -hree windings insulation breakdown arcing and so on
-Thus is a product of (5 transformers)(5)(10) 9 25(10)
Block 14 X (475((250) = 19(10)-9
94
8b Rationale for Use of the Selected Failure Rates
The component part failure rates utilized for the program are
based on failure rates taken from the high reliability Minuteman
ballistic missile program somewhat modified by Hughes using engineering
judgement These failure rates (detailed in Hughes Document R22-100DC)
were originally set up for the Hughes Space Satellite Systems They
basic rates modified as necessary toare utilized for this program as
allow for the estimated environmental stresses (temperature electrical
etc) that the system is expected to encounter in flight These basic
failure rates are then adjusted as a set by the Hughes Experience Factor
(E-factor) described below
8bl) E-Factor Usage
It is Hughes practice to modify the basic set of failure
rates by a prediction factor
E = k = observed failures
7t expected failures11
based on flight experience of Hughes Satellite Systems (Syncom II
Syncom III Early Bird Intelsat II-Fl F2 F3 and F4 ATS-l 2 and 3)
Multiplication of the basic set of failure rates by the E-factor in
effect will correct any optimistic or pessimistic bias in the basic
rates This utilization of the E-factor when significant differences
between the flight experience rates and the basic rates are observed
will cause the basic failure rates to converge to true values The
technique is asympototically unbiased regardless of the validity of the
originally assumed basic failure rates The data from the HAC Space
Satellites are considered applicable to the subject program as the
mission environments are similar and long time service and essentially
free-fall operation are also involved here The Hughes Satellites
95
8b1) (Contd)
to date have accumulated over 650 million operational component
hours and 6ver 400 million component hours in the dormant stage
The current value (as of 31 August 1968) of the E-factor is 0475
8b2) Internal Temperatures
Based on design considerations and calculations which
were confirmed by experimental-tests in a vacuum chamber the
componentt mounting base plate temperature will be at +250C +
50 and-the junction temperature of semiconductors at plusmn350C + 50C
except for the Control Module where the temperatures will be +20 0C
+ 250C respectively The utilized failure rates were subjected to
(and modified by) derating curves in the aforementioned Hughes Document
R22-100DQ In order to assure stability of these temperatures the
system is designed so that the solar panels will always face the sun
while the power unit is always facing away from the sun
8b3) External Environment
The space environment to be encountered by the system
in flight is considered to be gentler than that experienced by the
presently operating Hughes Space Synchronous Satellites The only
large consideration is exposure to radiation from the Van Allen belt
The effect is judged to be very minor for the subject system whereas
the Hughes Synchronous Satellites see the radiation for several days
while in transfer orbits Even though this system could encounter solar
flares in flight these are not considered as potentially harmful as the
Van Allen belt radiation
8b4) Part Selection
The component parts used in the subject system are highshy
reliability parts selected from a JPL Preferred Parts List The specifishy
cations for these parts have extensive and stringent reliability-proof
test requirements which appear satisfactory to assure procurement of
high reliability parts for the program
96
The reliability proof tests include among others
a) qualification tests such as - soaking at temperature extremes
humidity shock hermetic seal plus-a high temperature test to
demonstrate with 60 percent assurance that a tested lots
failure rate is less than I percent per 1000 hours and b)
quality assurance tests such as - life stability environmental
plus final visual and electrical tests
8b5y Conclusions
The computed reliability of 09702 for 10000 hours is
somewhat higher than the design objective of 096 and somewhat
lower than the proposal estimate of 09826
The drop from the proposal estimate is substantially due
to increased complexity resulting from mugh tighter regulation
requirementsintroduced by JPL during the negotiation phase for
Screen and Accelerator supplies (no line regulation originally
required and5 to 10 percent load regulation required respectively
now + 10 percent for line and load) A small drop in reliability
is due to somewhat higher temperature stresses than originally
assumed in analysis for purposes of simplified analysis
The present calculation should not be considered as
representing the best effort at optimizing reliability since it
represents an interim cut at the total system Now that a
detailed analysis has been made it will be apparent which areas
deserve the most attention in reducing failure rate and a tradeshy
off study may be made on cost in efficiency andor weight
Possibly in some areas it may be desirable to substitute lower
failure rate components ie a digital gate plus discrete
transistor for an integrated circuit op-amp Also closer
97
examination of stresses should result in lower failure rates
since in many cases components are at substantially lower stress than
than those assumed in this conservative calculation
98
9 Physical Design
a e
l-Cirawing X318810-500 Tnstallation Control for oucline and mounting
s of the assembly As indicated maximum dimensions are 36 x 30 x 378
Synte is designed for mounting from four (4) edges of the assembly with one
prt point in cunter of rear face Cover is removable from the-back without disshy
ni the acmbly making accessible components and circuit connections which are
wtd up Qu rtar face of individual module plates
Jic systt consists of an assembly of twenty (20) modules mounted on an egg-
Cis structure Individual modules are removable from the front after disconnecting
fN 1ar ss connectors on rear face
ront face of assembly i electrically dead wth protruding power transistor
s aad nust cqvercd by epoxy conformal coating All other components and connections
Iubehfld module plates Thus the assembly with its cover is totally enclosed to
provide MI shielding and freedom from high voltage hazard during testing
M|hcclear front face facing space in a vehicle provides sMielding from incident
iadiation Since in a typical vehicle ipstallation the rear of the assembly would be
Mhce from radiation by the vehicle structure and other poter conditioning assewsli es
tie back cover lay be perforated to reduce weight and permit free outgassirg thereby
pre-ccting pressure build-up and transition to regions of voltage breakdown (pasehens
curve) (Although all materils are selected for low outgassing)
All external connections are made at connectors located at one end of assenbly
with all low voltage connections in one corner made with space approved sub--minaturn
rectangular connectors All high voltage connections are made at the other corner to
high voltage standoffs with screw terminals These connections are made behind a
reijovable small connection cover
The various modules used in the system are sized in frontal area for a worstshy
case thermal radiation of 03 watt per square inch all from che front face assuming
no radiation from rear face a conservative assumption since in a typical vehicle the
vehicle structure to the rear is expected to be at a lower temperature than the Power
Conditioner with sowe radiation from the rear At this level of radiation with no
solar incidence a worst-case plate temperature of 350 C may be expected providing
high reliability operation of components which with few exceptions are mnunted on the
module plates
With the design philosophy of icw Wattssquaru inch each module is therurlly
self-sufficient and will not require conduction to structuun and sharing of radiation
area between modules Thus hot spots are mipimized
99
Since high reliability is obtained by extensive use of redundant or standby
circuits the thermal design philosophy has resulted in packaging of redundaft cirshy
cuits on same module plate with operating circuits intermixing the components on
the plate to obtain uniform thermal density regardless of whidh circuit is operating
b SUPPORT STIUCTURE
Refer to HAG Drawing X3188101 Frame Module
This supporting frame forms an eggcrate structure with a structural web or
I beam running between all modules and a channel section forming the edges Roles
located in I beam webs reduce weight without significantly reducing the section
modulus In order to provide a flat surface for module mounting the structure is
formed by assembling front and back plates with module cut-outs with webs intershy
laced in eggcrate fashiof the whole being dip-brazed Material is 0040
aluminum 6061T4 chosen rather than lighter magnesium to permit dip-brazing of
thin sections A riveted magnesium structure of the same strength would be
heavier
A stress analysis has been made of the structure (See Appendix) using conshy
servative simplifying assumptions of no contribution to strength from attached
module plates and no reduction of stress due to interlacing of beams This
analysis shows that structure is more than adequate to survive vibration at launch
phase
Module mounting screws fit into steel Pem nuts riveted to frame providing
a lightweight fastening which will permit frequent replacing of screws without
damage to threads The many screws provided will result in significant damping of
the structure in vibration as well as permitting ready replacement of modules
during test or service
Riveted Pem nuts are also used along edges of structure for niounting
c NODULE ASSE1l-LIES
1 Screen Inverter (See HAG Drawing X3188104)
As indicated under General discussion module is sized for a thermal
radiation of mwatt per square inch Since this circuit will dissipate 218 watts
for 300 watts out in-worst case of one module failed out of eight or 190 watts
for normal operation an area of 705 in2 will result in 027 wattsin2 or 250 C
normally or 031 wattsin2 maximum With an operating plate temperature (maximum)
of 350 C
Principle sources of dissipation have been separated in the assembly to
minimize local hot spots ie power transistors output transformer and output
rectifiers
6S57-CC-EN RFV 3-5I 100
Large area available pormits mounting all components on base plate which is
0050 sheet magnesium for low weight and maximum thermal conductivity per weight
To obtain good thermal conductivity yet conservative insulation of
components the area used by small components is covered with a 1 mil sheet of
Kapton (H-Film) bonded to plate with epoxy adhesive Thus the component may be
placed against plate and when conformally coated with epoxy will be thermally
intimate with plate solidly anchored against vibration and sealed against moisture
with a minimum of weight
To provide good thermal interface and security from vibration transformers
and output rectifiers are bonded with a thin layer of RTV in addition to mounting
screws RTV is sealed against out-gassing by epoxy conformal coating Use of RTV
for bond will penit ready replacement of component if necessary during tests
The method shown for mounting power transistors is subject to tests in
vacuum to confirm this technique Previous practice of using beryllium-oxide washer
and indium foil is subject to question due to possible cold-flow of indium and
resultant opening up of interface The relatively low wattage dissipated per transistor
(approximately 3 watts) permits use of Kapton with its lower thermal conductivity
than Be-O (even with I mil vs 0060 Be-O) Similarly it is believed that a thin
layer of RTV in interfaces may be superior long-term to indium foil
Low-voltage connections are made through a sub-miniature rectangular conshy
nector shown at bottom edge High-voltage connections are made at top to two
stand-off screw terminals
2 H ig-Voltage Filter (See Drawing No X3188114)
This assembly consists of the Screen and Accelerator Output Filters and
and bleeder resistors with voltage and current sensing networks -Since Screen
output is at -2000 V special attention must be given to voltage isolation
The bleeder resistors RI R2 R4 and R5 are potted in epoxy in a plastic
case The cases therefore provide a convenient mounting for the mica capacitors
which are shunted across the bleederOases provides a positive thermal path for
losses in the capacitors which are flat with a good interface and also provides a
secure mounting for vibration
Low voltage components are mounted in the fashion described for the Screen
Inverter
High voltage input and output connections are made at stand-off screw terminals
with low voltage connections through a rectatgular sub-miniature connector
Magnetic components and bleeder resistor assemblies are bonded to chassis for
goud thermal interface and resistance to vibration
d5-7 CC nv 3-5 101
Entire assembly will be conforirally coated with low-outgassing epoxy
Loss on this assembly will be approximately 5 watts Thus with area of2 2a
386 in2 and 0135wattsin temperature will be between 0 C for a free body and
50 C of adjacent modules
3 5 IQlz Heater Inverter (See 11AC Drawing NoX3188110)
This assembly is typical of design of inverters with standby cirshy
cuits where the operating and Standby inverters are packaged on the same
plate making the thermal radiation area available equally to either circuit
In this case a common output transformer is switched between inverter circuits
In normal operation transistors Q6 and Q7 will be on In standby transistors Q12 and
Q13 will be on It is thus apparent that a symmetrical thermal distribution is
presentin eiLher case With a dissipation of 9 watts expected and an area of 5 2 2 0
475 in or 019 wattsin a plate temperature of 5 C would result for a free
body or close to average system temperature of -_) C when mounted Mounting of
small components pox er transistors and mignetic components is similar to that
described for Screen Inverter
4 Accelerator Inverter (See h1AC Drawing NoX3188106)
This chassis similar to the 5aiGz inverter except for two (2) output
transformers and two (2) output rectifiers (21 T4 CR8 CR15) High voltage outputs
are brought out to two (2) stand-off screw terminals To share radiation area
equally between operate and standby conditions active components are staggered
Thus in operate Q7 Q6 T3 and CR8 will be on in standby Qi3 Q12 T4 and
CR15 will be on
In a transient mode at system turn-on dissipation will be-14 watts whereas
steady-state dissipation will be less than 3 watts At 429 in2 therefore and 14 2 0
watts or 029 wattsin final value temperature would be 35 C a safe value
However since transient should not last more than 15 mfnutes and thermal time constant
will be about one hour expected rise in 15 minutes is 1560 x 063 x (35 - 0) = 550 C
rise above assumed 00 C starting conditions free body
At 3 watts or 0078 wattsin2 a final temperature of -50 C would be expected
for a free body or closo to the average temperature of the system (about 20deg C)
5 Line Regulator (51Iz and Accelerator) See BAc Drawing No X3188118)
This assembly is identical in layout for the 5kilz and Accelerator
applications
At a loss of 105 watts worst case steady-state for the 5Kz applications 2and an area of 386 in or 027 wattsin 22 tmperature will be 250 C free body
8 4 1025-CC-EN RE 3-81
Components are mounted with techniques similar to those described above
6 Arc Inverter and Cathode Inverter (See HAC Drawings X3188108 X3188112)
These inverters are similar in layout differing in only the few small
components associated with output telemetry and feedback Techniques are similar
to those described above for the 5Kqlz and Accelerator inverters where -radiating
area is shared between operating and standby inverters
Dissirationii will be approximately 12 watts for the Cathode inverter and 2 215 watts for the Arc inverter With 479 in of radiation or 025 and 031 wattsin
respectively free body temperatures would be 200 C and 350 C respectively
7 Arc Rectifier and Filter (See HAC Drawing X3188116)
This module is a unique case of mounting relatively high dissipation
components at high voltage- This applies in particular to the output rectifiers
CRI CR2 and CR3 which dissipate 7 watts at a potential of 2KV To accomplish
the firm objective of good thermal conductivity and good insulation the rectifiers
are mounted on a magnesium bracket which is bonded to an epoxy-glass insulator
in turn bonded to the chassis By providing a liberal interface area of 3 in2
between -bracket and insulator a temperature rise across interface of 60 C will
result quite acceptable for the components with a plate temperature of 250 C The
latter results from a total dissipation of 10 watts with an area of 386 in 2 or 2
026 wattsin
Choke L2 is a source of about 3 watts and is a ferrite cup core directly
heat-sunk to chassis with high-voltage insulation internally
Capacitor Cl is a tantalum type which will dissipate about 1 watt due to
high-frequency ripple losses It is mounted in a fashion similar to that used for
rectifiers
Note that a inch creepage path is maintained between high-voltage elements
and chassis a desirable minimum to prevent flash-over
Except as noted other techniques are similar to those described before
S Magnetic Modulator (See HAC Drawing X3188122)
This is an assembly of magnetically-regulated supplies ie Vaporizer
Neutralizer Heater Neutralizer Keeper and Magnet Supplies The only supply at highshy
voltage is the Magnet with its output at a reference of + 2KV Estimated total 2 2dissipation is 48 watts with a radiation area of 395 in or 012 wattsin thus
an expected plate temperature of 10 0C free body or closed to average temperature of io C mounted
103
66857-CC-EN REV 3-51
Thus the mounting area required by components is the limit in this case
rather than temperature As indicated in drawing all magnetic components the
principal source of dissipation are mounted on chassis with small components
mounted on a plate above the magnetics with a thermal path to base plate through
corner posts
The components requiring high-voltage insulation are th6 output diodes of the
Mgnet Supply Using a technique similar to that described before for the Arc
Rectifier these diodes are heat-sunk to a small magnesium plate which is bonded
to a 0032 epoxy-glass insulator in turn bonded to a supporting magnesium bracket
which donducts heat to main plate (approximately 1 watt) A one-half inch creepage
path is provided between the diode heat sinkand the bracket across the epoxy-glass
A thin 0002 H film layer insulates the diodes from the heat sink and thus
from each other The bracket also carries the high-voltage screw-terminal standshy
offs for the magnet output
Techniques for mounting magnetics and small low-voltage components are
similar to those described for other assemblies
9 Control Module (See HAC Drawing X3188120)
This module is an assembly of low power components both discrete and
micro-circuit Nevertheless all components are mounted to heat sinks with defined
conductive paths to the base plate radiator Total watts dissipated is estimated
at approximately 5 watts maximum Hence temperature of assembly will be controlled
primarily by heat conduction from adjacent modules and should be close to the average
temperature of the system ie about SO0 C
Discrete components are mounted on a 132 epoxy-glass terminal board bonded
to a magnesium heat sink All components will iest on terminal board and will be
conformally coated with low-outgassing epoxy to improve heat transfer seal against
moisture and secure against vibration during launch
Microcircuits used here will be of the flat pack type and will be mounted on
a printed circuit board with an etched copper heat sink for a good thermal path to the
main heat sink
10 Low Voltage Connection Module (See HAC Drawing X3188127)
This module will mount all low voltage connectors interfacing with vehicle
connectors ie Control and Telemetry Low Voltage Loads and Input Power Conshy
nectors are all of the Sub-Miniature rectangular type rated at 5 amps per contact
All internal connections will be made at the rear of the assembly and all
external connections on the front face Each connector used is a different size from
adjacent connectors to prevert interchange of connectors
6O5 7-CC-EN REV -51 104
Harness connectors will be provided with side access covers for maximum
convenience in routing vehicle harness from edge of assembly
11 Hji Voltaga Connection Module (See HAG Drawing X3188126)
This module will mount all high-voltage connections to vehicle harness
Connections used are high-voltage standoff screw terminal type for minimum weight
compatible with high-vbltage insulation A protective cover will be provided for
personnel protection during tests
d ISCELTANEOUS GONS DEIRATIONS
1 Thermal
System thermal design philosophy was discussed under General and
detail thermal design was discussed under each module discussion For overall 2
sunmmations Figure 1 attached gives heat loads for each module wattsin and
expected temperatures
Although not indicated in drawings an array of power resistors will be
arranged throughout the eggerate frame to be powered from vehicle control to
pre-heat assembly to -20deg C before starting up system and insure minimum-temperature
above -40 C at any time
2 Choice of Materials
Two (2) criteria have been used in selection of materials over and above
the usual criteria strength insulation etc These are 1) low outgassing and
2) compatibility with Freon to be used in Calorimeter test Choice of materials for
first criterion are based on extensive data collected by HAG Materials Laboratory
Choice of materials for the second criterion has been made on the basis of tests for
24 hours immersionf in Freon at 450 C (expected operating temperature) and previous
experience with Surveyor batteries in Freon Calorimeters These tests indicate that
RTV is incompatible hence must be sealed with epoxy (only hair-line joints must be
sealed) However nylon adhesive mylar film H film teflon and epoxy have been
verified as compatible insulations
105
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d Miscellaneous Considerations (Contd)
3 Gas Density Calculation for Arc Dischtrge Versis Altitude
Problem
Find the maximum gas density that will accumulate in a vented power
conditioning housing of 47000 cm The gas being generated by the outgassing
rate of a conformal coating The vented area being a mesh screen plate with2
an atea of 6800 cm The holes in the mesh represent 40 percent of this area 2 or approximately 2700 cm
Given
The Components and Materials Laboratory at Hughes Aircraft ran some pre-shy
liminary tests on the conformal coating (used on the power conditioning comshy
ponents) with the following results
a) The outgassing molecules consist of water and various absorbed
gasses
b) The molecular weight averages 100
c) Approximately 3 x 1019 moleculescm 2 does outgas from a coating
0005 inch thick
d) Temperature of the gas is 3280 K
e) Approximately 0001 weight loss occurs in the first four hours in
space This is the maximum rate loss expected This is equivalent 6to 70 x 10- grams per second
f) The vented power conditioning housing contains 47000 cm3
g) One side of the housing is a mesh plate with a total hole area of e22700
Find
The maximum gas density developed inside the power cohditioning housing
after launch and injection in orbit Plot results on a gas density versus
altitude from the surface of the earth (Figure I)
Solution
1 Molecular velocity of the outgas is
-2 3R TVag = mM
1 6Vag 2 = 3 x 138 x 10 x 328 x 10 2
166 x 10-23
Vag = 286 x 104 cmrsec
whez k = Boltzmanns constant
107
SDensity Calculation for Are Discharge Versus Altitute
T- absolute temperature in kelvin
m = molecular mass (grams)
vag =velocity in cmsec
2 The maximum gas density developed inside the housing R
-=K A vag
61070 x
05-x 2700 x 103 x 286 x 104
= 181 x 10 13 gramscm
3
3 x 10-
1 2 slugsft-36
where R = gas flow rate in gramssecond2
in cmA = vented area
vag = gas velocity in cmsec
K =-flow efficiency taken -as 05
Conclusion
The maximum gas density developed inside the vented housingcontaining the -12
power conditioning system is approximately 36 x 10 slugs percubic foot
This value corresponds to an altitude of 100 to 130 nautical miles on an
atmospheric versus altitude graph
Gas Pressure Calculation
Using the ideal gas law
Pv= n k T
x 1014 x 138 x 1016 x 328
47090 x 104
P = 49x 10-4 dynes-cm
2
or P = 49 x 10-I0 atmospheres
or 7P - 376 r 10 shy mm Hg
where P-= pressure in dynexcm2
v = volume of 47000 in3
n = number of molecules in v 51 x 1014
k = Boltmanns constant 138 x 10-16
T abs temperature 328 0 K
108
Gs Pressure Calculation
Conclusion
Thevoltage breakdown for the power conditioning system will be above
10000 volts for 05 inch terminal spacings See Figure III
109
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10 POWER CONDITIONER SUPPORT EQUIPMENT SYSTEMS TEST CONSOLE
a General
The test console will operate test and evaluate the power conditioner during design de elopment qualification and acceptance testing
It provides the following basic functions
1 Simulated loads for the power conditioner Each of the eight power supplies are terminated in the correct impedance to operate the power conditioner and evaluate its performnce
2 Power input to the power conditioner power supplies Four power supplies provide power to the poier conditioner An array of switches applies and removes power from each group of inverters A master switch removes all power Selector switches are provided to remove power from individual inverters to simulate failures and demonstrate the abiliLy of the reserve circuits to cut in and mainshytain operation
3 Instrumentation for monitoring voltage current waveform and temperature All instrumentation consists of standard commercial equipment All pertinent voltages currents and waveforms can be selected and displayed on the appropriate drgital voltmeter ENS voltmeter andor scope Provisions for continual scanning and monitoring of 10 thermistors are provided
4 Continual telemetry monitoring All 15 telemetry outputs arc terminated and individually monitored at all times
5 The command generator will provide control conimands to the power conditioner The commands are 22 VDC positive pulses of 60 milliseconds duration (internally adjustable from 40-100 milliseconds) Any one of five command circuits can be selected Command status is displayed by lights on the status panel A 0 - 5 V analog command is provided continuously for screen reference current
6 High voltage protection of personnel is provided by electrical interlock and shorting relays in the -2 KV and + 2 KV high voltage areas within the test console
The test console block diagram displays the interconnection and flow between the above described functions
The instrumentation by selector switch monitors the voltage current and wave-form of all eight dummy loads In order to measure the relatively low voltageshyand currents which are at 2000 volts with respect to ground under normal operating conditions a meter enabling circuit has been provided This circuit allows DVM or EMS meter connection only when all high voltage has been removed The telemetry readout will provide continuous monitoring of all load voltages and currents All loads for the power conditioner are provided by the test console or transferred to the ion engine by the test console This will enable the operator to recheck the calibration of the telemetry at any time that it should become necessary during the test with the ion engine
REV 3-6s16637-CC-EN
The arc test will short any two supplies or any supply and ground by a thyratron
ischarge when so commanded There are also provisions to apply a direct short or
xternal resistance between any two supplies or any supply and ground
A main three pole circuit breaker is provided to remove all power Individual
ircuit breakers are provided for the 28V pouer supply and the arc test power nput- All instrumentation and the remaining power supplies are commercial units
ith front panel switches
FUNCTIONALCIRCUIT DESCRIPTI
Schematic diagrams of the various circuits comprising the test console are ttached
1 Control Panel
The DC power distribution consists of a main disconnect switch and five ower conditioner power disconnect switches As each switch is closed an indicator
amp will glow on the status panel indicating the presence of power
The main DC power switch is a DPDT center off switch The upper switch
esition connects the four main power supplies two in series and two series groups n parallel The lower switch position connects a9l four in parallel The relay ontacts for each pair of power supplies will carry 60 amps
All high voltage supplies are interlocked by a series string of switches
he switches are placed on all access panels to high voltage areas When a panel s removed the associated switch will open This will open the circuit to the igh voltage warning lamp and a relay that disconnects power to the high voltage upplies The meter enable switch on the high voltage panel disconnects the etering circuits on the magnet (VI) cathode (V3) and anode (V4 ) loads This ircuit is discussed in a separate section The scope digital voltmeter and
rue PNS Voltmeter selector switches are located on this panel The Arc Initiate ommand and Command Selector are located in this panel They are discussed in eparate sections A means of disconnecting the power to all active inverters to imulate failurewill be accomplished by opening the selected switch A failure n the 5 KC Cathode and Arc Inverters is simulated by disconnecting the drive ith a relay located near the power conditioner
2 Comiiand Generator
The Command is initiated bya momentary on push-button switch This pplies 28 volts across the 10K Q and 47 f time delay network With the 10K 0 esistor adjusted to 58K Q the transistor will conduct enough to energize the elay in 60 milliseconds The result is conmand circuit providing a positive DC 2 volt pulse of 60 milliseconds duration with less than a one millisecond rise and
all tine 4K resistors are provided to effectively ground the command circuits and
enerator when they are not selected or commanded The second contact (normally open)
f the relay provides a means of displaying the command status
113-Crrr-jnr $-8
Off 2 must be comanded first or no DC power will be available to the power conditioner The Off 2 status light will remain lit (after command) until the selection switch is changed As On 1 On 2 and On 3 conmmands are enabled
a status light turns on for each When Off 1 is commanded the Off I status light turns on When On 3 is commanded (this light is already on) the Off 1 light -turns off Off 2 command turns off all command status lights except Off 2 A zero to five volt DC analog command is provided for screen reference current
3 Telemetry Panel
Fifteen telemetry outputs are monitored continuously They are terminated P90K ohms This termination and the source impedance will provide a 5 volt indicashytion on the 50ga meter for a 5VDC signal Switches are provided at each meter to momentarily disconnect the meter load for more accurate readings on the DVM
4 DC power is supplied by four 40V 30A fast response power supplies connectedshyin series parallel for normal operation or in parallel for low voltage operation
5 Arc Test
A thyratron tube is used for the arc test When energized it can be disshycharged by depressing the Arc initiate momentary on switch This energizes a conshytrol relay and applies a positive voltage to the grid circuit driving the thyratron into full conduction Conduction will cease when the anode-cathode voltage drops to a very low level or the initiate switch is released which opens the anode circuit An RC network in the grid circuit limits the time the grid remains positive to less than 10 milliseconds
6 Meter Enabling Circuit
All voltage mbnitoring is done at the power conditioner andnot at the loads (except the cathode) It is necessary to protect the instrumentation from the applishycation of 2000 volts when either the screen or accelerator supplies are operating A 101 voltage divider is provided to measure 2 KV screen and accelerator voltages A meter enablingcircuit is provided to protect the instrumentation by disconnecting the instrumentation with high voltage relays Under normal operating conditions the magnet (VI) cathode (V) and anode (V4) loads are connected to the +2KV screen supply When measurements are to be made on these supplies they are disconnected shy
from the screensupply and grounded The parameter to be measured is selected by a seven position selector switch This circuit also prevents measurement at 2 KV when the power conditioner is not connected such as when the load is transferred to the ion engine This protection is required because all voltage monitoring is done direct This circuit uses the ground leg of the vaporizer supply (V2) to connect or disconnect the +28V transfer voltage A red status light indicates when the circuit is disconnected
7 -Magnet Load (Vi)
The magnet load consists of a variable 4 ohm rheostat in series with a 7 mh choke and a 185 ohm resistor The magnet load can be varied from 185 ohm cold to 225 ohm hot This load is connected to the screen supply except when the instrumentashytion is in use Provisions are made for open circuit short and arc short to any
supply and ground
14
8 Vaorizer Load (V_2
This load consists of a 5 ohm non-inductive resistor It can be open circuited shorted and arc shorted to any supply and ground
9 Cathode Load (V3)
Provisions are made to mount the output transformer supplied with the power conditioner within the test console The SERT IT vaporizer and cathode loads were combined and rearranged to form this load A breadboard was made The best circuit arrangement consisted of seven parallel strings of three series 866A tube filaments shunted by approximately 0-28 ohms The test arrangement consisted of this load a 40A current limited DC power supply and current and voltage recorders Current was constant at 40A (except for initial surge) Voltage was 18V cold(0045 ohms) 28V in 8 seconds and stabilized at 42V after 90 seconds (0105 ohms) The 0045 ohm cold will be reduced to 0035 ohm by increasing wire size and reducing lead length The center tap of the output transformer is connected to the arc load Provisions are made to short and arc short to any supply and ground
10 Arc Load (V4)
The large rheostat from SERT II anode load and 11V selector switch from the vAporizer keeper load were retained for this load The load consists of a 5-position step switch and a combination of resistors and the rheostat The load terminals are connected one to the cathode supply and the other to the screen supply via the meter enabling relay The 5 positions will provide a load of 1) open 2) _2 ma 150V (75K ohms) 3) 20 ma 30V (1800 ohms) 4) al to 29A (124 to 474 ohms) 5) 58 to 84A (57 to 43 ohms) It can be shorted and arc shorted to any supply and ground Note The plus lead will not be cormmon to the screen lead at the power conditioner provisions for this connection are made in the meter enable circuit of the test console
11 Screen Load_(V5)
Many of the resistors and the high voltage relays from the SERT II console are used in this load Most of the resistors are operated at their published maximum wattages therefore a 700 CFM exhaust fan will be added at the top of the console inmediately above this load to keep these resistors at below their rated temperatures Three resistance banks are used in parallel combinations to provide loads at 2 KV of 1) open (divider in meter circuit will draw 1 ma) 2) 01 to 058A 3) - 068A 4) 08A 5) pOS4 to 106 A A make before break selector switch is used to make selection This load can be shorted and are shorted to any other supply and ground A 0-075A current limited supply can be connected across the screen current sensing resistor in the power condition to simulate an analog load condition in the active range of the screen supply
12 Accelerator Load (V6)
This load consists of a 5-position selector switch and resistors which will provide these loads at 2KV 1) Open (divider in meter circuit will draw 1 ma) 2)
105 ma (188K) 3) 53 ma (38K) 4) _ 77 ma (26K) 5 01 to 011A (20K to 18K) This load can be shorted and arc shorted to any other supply and ground
GM 7-cc-EN FEV 3-61 115
13 Neutralizer Cathode and Neutralizer Vaporizer Load (V7) (Same as SERT II)
The neutralizer cathode and neutralizer vaporizer loads consist of seven 866 tube filaments wired in series with an additional seven series connected 866
tube filaments shunted by one 1651 lamp (5V at 06A each) This circuit is an analytical design based on data received from the breadboard of the SERT II vaporizer load circuit The mathematical results show the following
a) The initial cold resistance should be 12 ohms
b) The final (after 10 t1me constants) resistance will approach 53 ohms Note that the one time constant resistance is 38 ohms
c) One time constant will be 40 seconds
116
The specification requires a cold resistance of I ohm a one-rime constant resistance of 35 ohms and a one-time constant value of 30 seconds
14 Neutralizer Keeper Load (V8 ) (Same as SERT IT)
This load consists of a potentiometer and a high-voltage transistor Adjustshyment of the potentiometer will cause the transistor to load the supply in the range of from approximately 300V minimum to 2V with a corresponding change in current of from approximately 0 ma to 500 ma A vernier adjustment is provided for
15 Status Panel
The following indicator lamps are displayed on the status panel
Status Panel Lamps Color
a) Warning Ihigh Voltage Red b) On I Green c) On 2 Green d) On 3 Green e) Off I Green f) Off 2 Green g) Main AC Power Neon (Amber) h) Arc Test Power Neon (Amber) i) 28V Supply Power Amber j) Main DC Power Amber k) Line Regulator Power Amber 1Y Cathode Power (V3) Amber m) Arc Power (V4 ) Amber
n) Screen Power (V5) Amber o) Accelerator Power (V6 ) Amber p) -2KV Shorting Switch Closed Red q) +2KV Shorting Switch Closed Red r) Short Test On Red s) Meter enable not ready Red
c HARDWAREPACKAGING DESCRIPTION
The test console will be housed in two 6 foot rack cabinets 25 inches deep There will be a work shelf at approximately 29 inches from the floor A pictorial diagram is included Custom equipment will be placed as indicated in the pictorial diagram Location of controls is approximate and will be determined during the mechanical design phase of this program
d ENERGY NEEDS AND LOSSES
Energy requirements of the test console will be supplied by 120208 VAC 3shyphase power source Current loading will be divided between the three phases as equally as possible
Two blowers and filters will be installed at the bottom of the cabinets to cool the test console An exhaust fan will be installed over the high voltage section to adequately cool these components
6657-CC-EN REV 3-61 117
LIST OF DRAWINGS
POWER CONDITIOiMR TEST CONSOLE (BLOCK DIAGRAM) Fig 10-1i
CONTROL (SCOIFMATTC) Fig 10-2
COMMAND -ENRATOR (SCmTMATIC) Fig 10-3
TEIII-tTRY PANEL (SCHEMIATIC) Fig 10-4
ARC TEST (SCHEMATIC) Fig 10-5
METER ENABLING CIRC-IT FOR VAPORIZER ThRUSTER CATHODE Fig 10-6
MAGNET LOAD (V1 ) (SCUEt1ATIC) Fig 10-7
VAPORIZEIR LOAD (V2 ) (SCHISMATiC) leig 10-8
CATHODE LOAD (V3) (SCPEIMATIC) Fig 10-9
ARC LOAD (V4 )(SCHEMLATIC) Fig 10-10
SCRIEN LOAD (V5 ) (SCHEIINAIC) Fig 10-11
ACCEI3_RATOR LOAD (V6) (SCHEMhATIC) Fig- I0-12
NEUTRALZBR HEATER LOAD (V7 ) (SCHEIItTIC) Fig 10-13
NEUTRALIZER KEEPER LOAD (V ) (SCFEWTIC) Fig 10-14
CONSOLE DRAWING Fig 10-15
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D857
11 Isothermal Calorimeter
A calorimeteris being constructed for the purpose of measuring the operating
efficiencies of the power conditioner The calorimetric method of measuring
operating efficiences has the inherent advantage of measuring inefficiencies
directly so that a two percent error in measuring the inefficiency for example
would lead to an error in calculating the efficiency of less than 02 percent if
the efficiency is greater than 90 percent This assumes of course that the
input power can be measured to within less than 02 percent
The calorimeter is of the isothermal type which indicates heat generation
by measuring the rate of boil off of a liquid The liquid used is one of the
Freons (usually Freon 11 or Freon TF) because of their low toxicity non-flammability
and non-conductance The item under test is placed inside the inner chamber of
the calorimeter X3182788 This chamber and the surrounding one are filled
with Freon A hole in the bottom of the inner chamber connects the Freon in the
outer chamber with that in the inner one The Freon in both chambers is maintained
at the boiling point with heaters mounted in the chambers so that any additional
heat input to the system such as that from the item being tested will be seen
as an increase in the volume of the vapor The reason for the outer chamber of
Freon is to serve as a thermal insulator for the test chamber The Freon vapor
from both chambers is condensed in a condensor and returned to the outer chamber
The vapor produced in the inner chamber goes through a small orifice in the
lid and into the vapor space ii the outer chamber before going to the condensor
A very sensitive differential pressure transducer located on the lid to the inner
chamber senses the pressure difference between the inner and outer chambers
caused by Freon vapor from the inner chamber as it passes through the small
orifice into the outer chamber
When the item under test begings to generate heat the Freon flow rate inshy
creases which causes an increased pressure drop across the orifice The increased
output from the transducer causes the heater in the inner chamber to be turned
down and a constant flow rate of Freon vapor (and therefore a constant heat
outputfrom the inner chamber) will be maintained provided that the inner chamber
heater was originally set at some value higher than the anticipated heat output
of the item under test The circuit includes a zero suppression so that this
decreased is read directly This readout obviates any data reduction The heat
generation rates can be read directly on a strip chart recorder or they can be
sent to any other data storage system
134
In addition to the heaters which are part of the feedback system the inner
chamber also contains a calibration~heater This heater is used not only as a
dummy load for calibrating but also assists in the initial warm-up It can also
be used to maintain a positive heat output when measuring endothermic reactions
such as batteries under certain circumstances
This calorimeter has been stressed for pressurization to 15 psig with a
safety factor of more than 41 This is to allow a range of operating temperashy
tures to be attained By adjusting the pressure in the range from 0 to 15 psig
for example the boiling point of Freon 11 can be varied over the temperature
range from 24 to 45 0C
The assembly drawing is shown in Figure 1 The inner chamber which is
indicated by the dotted lines has the following dimensions
Length 40 (inside)
Width 10 (Inside)
Height 35 38 (Inside)
The maximum height available for an item being tested is about 32 inches because
the chamber must not be filled completely with Freon and the item under test must
be completely submerged
The total weight of the calorimeter is estimated to be 832 pounds empty
and 2257 pounds filled with Freon 11
Power input to the feedback heater will be controlled by an SCR which
senses the ignal from the differential pressure transducer The unit is the
135
12 List of Drawings
Drawing Number
X3188100-500 X3188101 (2 sheets) X3188103 x3188104 X3188105 X3188106 X3188107 X3188109 (2 sheets) X3188110 X3188111 X3188112 X3188113 x3188114 X3188115 X3188116 X3188117 X3188118 X3188119 X3188120 (2 sheets) X3188121-2 X3188122 X3188123 (2 sheets) X3188126 X3188127 X3188131 X3182788
Title
Installation Control Frame Module Plate Mounting Screen Inverter Assembly Screen Inverter Schematic Accelerator Inverter Assembly Accelerator Inverter Schematic Arc Inverter Schematic 5 KHz Heater Inverter Assembly 5 KHz Heater Inverter Schematic Cathode Inverter Assembly Cathode Inverter Schematic High Voltage Filter Assembly High Voltage Filter Schematic Arc Rectifier Filter Assembly Arc Rectifier Filter Schematic Line Regulator Assembly Line Regulator Schematic Control Module Assembly Master Oscillator amp Phase Shifter Schematic Magnetic Modulator Assembly
Magnetic Modulator Schematic High Voltage Connection Module Assembly Low Voltage Connection Module Assembly System Block Diagram Calorimeter Assembly Mark III
136
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