SIRIUS Power Converters:

Test of pre-series converters

Guillermo Navarro Patrón

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• Received one converter of each type.

• Qualification tests.• Visual inspection – Completed on all converters.

• Functional test – Completed on all converters.

• Heat run test – Completed on all converters.

• Performance test – Completed on SIRIUS-S and SIRIUS-2P.

• SIRIUS-4P: IGBT failure event under investigation. Possible infant failure.• Read functional test.

• Verify operation.

• Performance test.

• Production of SIRIUS-S ongoing according to plan.• 25 units in production. First delivery mid October.

• Storage space has been prepared in building 250.

• Qualification test platform for series equipped in building 287.• Building temporary unavailable for construction. Available in October.

Qualification tests

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Current status in factory

Sub-assembly of power converter parts

room

Assembly of power converters room

SIRIUS Power Converters:

Tester for series reception

Guillermo Navarro Patrón

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Flexibility.

One tool for all SIRIUS configurations.

Automation of test tasks.

No need for FGC3 crate.

User friendly and intuitive.

To be operated by factory personnel.

Standard connections (BURNDY).

Tests performed automatically.

Safe. Low voltage operation.

Portable.

Tester features

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Tester features

Architecture

HMI +

Interface

connections

PXI

Interface

board

Power source

output

Hardware integration

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PXI

PXI-8108: Controller. Enhanced with 4GB RAM and 128GB SSD.

PXI-4110: Power supply powering Interface board. Controlled from TestStand.

PXI-6509: Digital I/O. Controlled from LabVIEW.

PXI-6225: Analog I/O. Controlled from LabVIEW.

Interface board

Precharge relay control checked.

MCB manual operation checked.

IGBTs control checked.

Correct data acquisition checked.

Power source

Controlled with LabVIEW and TestStand.

Hardware integration

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TestStand:

Sequence manager.

Synchronization of LabVIEW VI’s.

Creation of results report.

GUI execution.

LabVIEW:

Execution of steps/instructions.

Monitoring variables.

Activating digital inputs.

Communication with TestStand.

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Test implementation

LabVIEW: Interface board

Single PWM Generation

Analog signals readout

Digital outputs command

Full H-Bridge PWM Generation

Digital inputs status readout

Data acquisition.

Data representation.

Filtering noise.

PWM generation.

Commanding switches.

Sending data and

commands to

TestStand.

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Test implementation

Three/Single-phase

configuration

Power source initialisation

Current level setup

Output activation

Output protection configuration

Output Voltage Mode

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LabVIEW: Power source control

Initialising source.

Configure output

protection.

Configure phase

mode output.

Set voltage and

current limits.

10V and 0.1A

Output activation.

Output values

measurement.

Test implementation

Main sequence:

· Main configuration

· Calls every test.

· Clean up.

· Main GUI call

Test sequences:

· One per test.

· Calls every VI.

· Test GUI.

TestStand

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Test implementation

Tests performed

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Test execution

100.000 - Digital interlocks

100.001 - MCB operation

100.002 - Boost Switch

100.003 - Fast Discharge Switch

100.004 - DC Link charge

100.005 - HB11 and HB22 switches

100.006 - HB12 and HB21 switches

100.007 - Crowbar operation

100.008 - Filter damping

100.009 - DCCTs operation

100.010 - Earth detection

Report

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Test execution

Test responsible operator information.

Date and time.

Total execution time.

Pass/Faill status of the whole sequence.

Actions/Steps executed and done.

Steps individual time.

Pass/Fail status of every test.

Measurement values.

Waveforms display.

Conclusion.

Current status

Hardware tested and fully verified with SIRIUS converters

Software implementation:

Sequences for testing digital interlocks implemented and verified.

Sequences for testing DC-Link Precharge implemented and verified.

Sequences for testing H-Bridge implemented and verified.

Debugging minor errors.

What’s next?

Compact even more the platform for easier transport and operation:

Trip to Electrotel (Romania):

Training of the responsible personnel of testing.

Start testing first batch of SIRIUS-S power converters.

Coordination and documentation of the qualification tests at CERN.

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