William A. Reass, James D. Doss, Robert F. Gribble, Michael T. Lynch, Paul J. Tallerico (LANL)
This paper describes the design and operational characteristics of a zero-voltage-switching 20 kHz polyphase bridge, boost converter/modulator for klystron pulse application. The DC-DC converter derives the buss voltages from a standard 13.8 kV to 2300 Y substation cast-core transformer. Energy storage and filtering is provided by self-clearing metallized hazy polypropylene traction capacitors. Three 'H-bridge' IGBT switching networks are used to generate the polyphase 20 kHz transformer primary drive waveforms. The 20 kHz drive waveforms are chirped the appropriate duration to generate the desired klystron pulse width. PWM (pulse width modulation) of the individual 20 kHz pulses is utilized to provide regulated output waveforms with adaptive feedforward and feedback techniques. The boost transformer design uses amorphous nanocrystalline material that provides the required low core loss at high flux levels and switching frequencies. Resonant shunt-peaking is used on the transformer secondary to boost output voltage and resonate transformer leakage inductance. With the appropriate transformer leakage inductance and peaking capacitance, zero-voltage-switching of the IGBT's is attained, minimizing switching losses. A review of these design parameters and a comparision of computer calculations, scale model, and preliminary first article results will be performed.
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