####### NSTX {#nstx .unnumbered}

SWITCHING POWER AMPLIFIER (SPA)

######  {#section .unnumbered}

######  {#section-1 .unnumbered}

###### NSTX-SPEC-5-84 {#nstx-spec-5-84 .unnumbered}

REVISION 0

September 24, 2003

PREPARED BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

C. Neumeyer

REVIEWED BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

S. Ramakrishnan

REVIEWED BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

C. Neumeyer

REVIEWED BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Quality Assurance

APPROVED BY:\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_\_

Supervisor / RLM

**PRINCETON UNIVERSITY**

**PLASMA PHYSICS LABORATORY**

**P.O. BOX 451**

**PRINCETON, N.J. 08543**

**609-243-2000**

#  {#section-2 .unnumbered}

# **SCOPE**

This specification is for a switching power amplifier (SPA) and input
filter capacitor to be used in a closed‑loop feedback system in the
National Spherical Torus Experiment (NSTX) plasma physics research
device located at the Princeton University Plasma Physics Lab (PPPL).

The SPA will be powered by a single 6-pulse thyristor rectifier DC
source power supply provided by PPPL.

The SPA Unit shall consist of three independently controlled sub-unit
SPA's which can be configured for operation as three independent units
or as a single unit. In all cases the SPA will be fed from the same
single DC source power supply.

Each SPA sub-unit shall consist of an H-bridge PWM inverter capable of
4-quadrant operation (+/-voltage and +/- current to load). See following
figure.

![](media/image2.pct){width="5.094444444444444in"
height="5.624305555555556in"}

# **APPLICABLE DOCUMENTS**

> ANSI C34.2 Practices and requirements for Semiconductor Power
> Rectifiers\
> \
> ANSI IEEE 18 Shunt Power Capacitors\
> \
> ANSI/IEEE 4 Techniques for Dielectric Tests\
> \
> ANSI/EIA RS-197-A Power Filter Inductors for Electronic Equipment\
> \
> ANSI/NEMA ICS 1 Industrial Control and Systems General Requirements\
> \
> ANSI C2 National Electrical Safety Code\
> \
> ANSI/NFPA National Electrical Code No. 70\
> \
> ANSI/IPC-A-610 Acceptability of Electronic Assemblies -- Class 2
>
> NEMA PV-3 Safety Code for Semiconductor Power Converters

# **REQUIREMENTS**

> Requirements for the SPA are delineated in the following paragraphs.
> Seller may elect to take exception to any of the requirements in order
> to achieve a more cost effective or technically superior solution.
> However, any exceptions shall be clearly delineated in the Technical
> Proposal.

## PERFORMANCE REQUIREMENTS

### Input DC

> PPPL will provide a 6-pulse thyristor rectifier DC source power supply
> with a variable (thyristor phase controlled) output. The connection
> between the DC source and the SPA will consist of a cable run of
> approximately 300 feet (per pole) of 500MCM cable in series with a
> 267uH inductor.

1.  Output DC

> The output ratings of the DC source power supply are as follows.
>
> DC Voltage: 0-1kV DC (adjustable via phase control)
>
> Peak of Rectified AC Voltage: sqrt(2)\*750=1060V peak
>
> Maximum Continuous Output: 3.25kA
>
> Maximum Pulsed Output: 24kA-6 sec once every 300 seconds
>
> Short Circuit Current: 60kA peak

2.  Load Circuit

> There are three independent load circuits. Each load circuit consists
> of a cable run of approximately 300 feet (per pole) of 500MCM cable in
> series with a load.
>
> Characteristics of load circuit including cable run are as follows:
>
> Resistance: R = 40 mohms
>
> Inductance: L = 100 uH.
>
> In all cases one SPA sub-unit will be connected to one load circuit.
>
> When configured for independent operation, each sub-unit shall follow
> its own reference input signal and shall be electrically separate from
> the other sub-units.
>
> When configured for parallel operation, all three sub-units shall be
> electrically paralleled via bus links internal to the SPA enclosure
> and shall follow a common reference signal.

1.  Pulse Output

> Output of SPA will be pulsed. Each sub-unit shall be capable of
> delivering a current pulse to the load as follows.
>
> Peak Current: 3.33 kA
>
> Pulse Waveshape: DC to 100Hz sinusoidal AC
>
> Pulse Duration: 5.0 seconds
>
> Repetition Period: 300.0 seconds

2.  Harmonics

> Harmonics in the load should be minimized by the PWM switching scheme
> and switching frequency. Seller shall describe propose switching
> method and estimate of harmonic content in the Technical Proposal,
> assuming operation at the full DC source input voltage (1kV).

3.  Control

> Each SPA sub-unit, or the three paralleled subunits, shall be capable
> of both closed loop current control and open loop voltage control
> modes of operation. Seller shall describe proposed feedback control
> method along with performance characteristics (accuracy, response,
> etc.) in the Technical Proposal.

1.  EQUIPMENT REQUIREMENTS

## Location

> The SPA will be located indoors, in a general access area and in close
> proximity to other power supplies. The indoor facility is heated and
> ventilated but lacks air conditioning. The maximum ambient temperature
> is 35^o^C

## Cooling

> If cooling water is required, PPPL will supply same with an inlet
> temperature of 20^o^ C maximum @ 90 psig. Vendor shall specify flow
> requirements with Technical Proposal.

## Reconfiguration

## Suitable bus links and switches shall be provided to configure the control and power circuits in the single SPA or combined SPA mode. Transfer from one mode to the other should require no longer than 4 hours when performed by two qualified technicians. {#suitable-bus-links-and-switches-shall-be-provided-to-configure-the-control-and-power-circuits-in-the-single-spa-or-combined-spa-mode.-transfer-from-one-mode-to-the-other-should-require-no-longer-than-4-hours-when-performed-by-two-qualified-technicians. .unnumbered}

1.  Controls

    1.  Local/Remote Control Selection

> The SPA will normally be monitored and controlled remotely. However, a
> local control capability shall be provided for test and maintenance.
> Provision shall be made for local/remote control selection locally at
> the SPA cabinet. Seller shall describe the local control capability in
> the Technical Proposal.

2.  Internal Fault Sensing and Interlocks

> The SPA shall be equipped with suitable sensing of faults such as
> over-current, over-temperature, etc., as required to ensure safe and
> reliable operation of the equipment. In addition, interlocks shall
> prevent mis-operation of the equipment when a fault condition exists
> and/or when the configuration of the equipment is not in the proper
> state for operation. Seller shall describe the internal fault sensing
> and interlocks in the Technical Proposal.

3.  Remote Control

    1.  Supervisory Input Signals to SPA

PPPL will provide a PERMISSIVE contact closure signal to the SPA if all
the external interlocks are satisfied. When the PERMISSIVE signal is
present, the SPA shall transition to a READY state (e.g. dump switches
on capacitor banks, etc., shall be lifted).

PPPL will provide a ENABLE contact closure signal to the SPA which shall
enable the firing of the gate pulses to the power electronics. Gate
pulses shall only be issued when the ENABLE signal is present.

PPPL will provide a RESET contact closure to the SPA which shall reset
any fault conditions which may be present.

All above digital inputs shall be opto-coupled at the SPA.

2.  Supervisory Output Signals from SPA

SPA shall provide a READY contact closure when it is in a READY state,
i.e. ready for capacitor bank charging.

SPA shall provide a FAULT NOT contact closure when it is in a fault-free
state. The contact shall open and remain latched in the open state until
receipt of a reset signal from PPPL supervisory control.

All above digital outputs shall be isolated contact closures or isolated
solid state switches capable of passing up to 1 Amp and withstanding at
least 24 V DC in the open state.

3.  Analog Input Signals to SPA

PPPL will provide three (3) +/- 10V reference signals which shall be
interpreted as a reference input command follows:

Current control mode: +/- I where I = 3.33kA in the single SPA mode or
10kA in the combined SPA mode

Voltage control mode: +/-V where V= full PWM duty cycle

4.  Analog Output Signals from SPA

The following analog output signals shall be available:

Current output from each SPA subunit (total 3 signals)

Output Voltage from each SPA sub-unit (total 3 signals)

Capacitor bank voltage (one signal)

Seller shall describe the method of current measurement, including
accuracy, filtering, etc., in the Technical Proposal.

4.  Isolation

> All control circuits shall be isolated from the power circuits and
> from any other source of high voltage by suitably rated insulators and
> grounded metallic barriers, or optical isolation. Isolation between
> the SPA and PPPL control circuits is to be provided within the SPA.

2.  Protection

> Self-protection for the SPA should follow the guidelines set forth in
> ANSI/IEEE Standard 444.

3.  Capacitors

> DC Link capacitors shall be sized to ensure adequate time response and
> low ripple in the system. Seller shall recommend a capacitance value
> as part of the Technical Proposal. Non PCB, input filter capacitors,
> with spill containment as applicable, shall be provided. Capacitor
> shorting resistor(s) and switch(es) as well as the necessary controls
> shall be provided such that the capacitor shall be automatically
> discharged on removal of PERMISSIVE command from PPPL supervisory
> control system.

4.  Insulation

> SPA shall be insulated to ground, between sub-units, and from power to
> control circuits based on 1kV operation and hipot at 2\*1+1=3kVDC.
> Nema PV‑3, Safety Code for Semiconductor Power Converters shall apply
> for electrical creepage and clearance.

5.  Enclosure

> SPA shall be supplied in a free-standing drip-proof metallic enclosure
> suitable for installation in a general access area. Provision shall be
> made for transport via forklift and lifting via lifting lugs located
> on the top of the cabinet. Enlosure shall meet NEMA 12 ratings for
> dust and moisture. overall size of the SPA shall not exceed 6 feet
> wide x 6 feet deep x 8 feet tall. Seller shall indicate actual cabinet
> dimensions and weight in the Technical Proposal. Enclosure shall be
> designed to segregate the control and instrumentation cable
> termination area from the power area via metallic barriers.

6.  Finish

> Cabinet shall be cleaned, primed and painted inside and out following
> good industrial practices. Seller shall indicate interior and exterior
> finish details (color, etc.) in the Technical Proposal.

7.  Construction

> SPA should be modular and utilize identical modules and components
> where possible. Modules shall be equipped with lifting devices and
> guides to facilitate removal and replacement.

8.  Nameplate\
    \
    Nameplates shall be in accordance with ANSI C34.2, modified to take
    into account the pulsed operating ratings (as well as thermal
    ratings).

9.  Grounding and Bonding

> Enclosure shall be so constructed as to constitute a single contiguous
> conductive shell, allowing for electrical contact between panels and
> frame via bolts and fasteners as applicable. Provision shall be made
> for connection of PPPL 4/0 ground cable.

## Identification and Marking

> Internal components shall be provided with identification and name
> tags for easy trouble shooting. These name tags shall be identified in
> the Seller's drawings.

## Cabling Interface

1.  Power Cable

> Cut-outs shall be provided at the top and bottom of the enclosure for
> power cable entry. Seller shall also provide copper pads to connect
> the power cables using NEMA standard 2 hole lugs. All power cable
> joints as well as the copper pads to receive cables shall be silver
> plated. PPPL will install two incoming 500MCM cables from the DC
> source via the bottom cut-out and six 500MCM output cables via the top
> cut-out.

2.  Control Cable

> SPA shall provide terminal blocks to receive AWG#14 control cables.
> Cut-outs shall be provided at the top of the enclosure for control
> cable entry.

1.  [TEST AND INSPECTION]{.underline}

## In-Process Tests

## Seller shall supply with the Technical Proposal a list of all dielectric, interlock, control, and dummy load tests that will be performed to establish compliance with this specification. PPPL reserves the right to witness factory tests. PPPL witness points shall be established prior to contract. A minimum of 1 week notice shall be given for tests to be witnessed by PPPL. {#seller-shall-supply-with-the-technical-proposal-a-list-of-all-dielectric-interlock-control-and-dummy-load-tests-that-will-be-performed-to-establish-compliance-with-this-specification.-pppl-reserves-the-right-to-witness-factory-tests.-pppl-witness-points-shall-be-established-prior-to-contract.-a-minimum-of-1-week-notice-shall-be-given-for-tests-to-be-witnessed-by-pppl. .unnumbered}

## Hipot Tests

> Hipot tests (3kV DC, 1 minute to ground) shall be performed on the
> completed SPA system one sub-unit at a time (total 3 tests), with the
> other two sub-units grounded, and all control circuits grounded.

2.  [QUALITY ASSURANCE]{.underline}

## Inspection/Surveillance/Audit by Customer

## Representatives of PPPL shall have the right to visit the Seller\'s premises during the performance of this procurement as stated in the General Provisions of this subcontract. The Seller shall make available records and documentation necessary for this function. PPPL recognizes the Seller\'s right to withhold information concerning proprietary processes. {#representatives-of-pppl-shall-have-the-right-to-visit-the-sellers-premises-during-the-performance-of-this-procurement-as-stated-in-the-general-provisions-of-this-subcontract.-the-seller-shall-make-available-records-and-documentation-necessary-for-this-function.-pppl-recognizes-the-sellers-right-to-withhold-information-concerning-proprietary-processes. .unnumbered}

## Changes to Customer Approved Documents

## Revisions or changes by the Seller to documents approved by PPPL shall be reviewed and approved by PPPL prior to use.  {#revisions-or-changes-by-the-seller-to-documents-approved-by-pppl-shall-be-reviewed-and-approved-by-pppl-prior-to-use. .unnumbered}

## Submittal of Quality Assurance Manual

## As part of the proposal, the Seller shall submit a copy of its Quality Assurance Program Manual, describing the Seller\'s quality capability and general approach to quality assurance. The manual is subject to customer\'s review and acceptance prior to contract award. {#as-part-of-the-proposal-the-seller-shall-submit-a-copy-of-its-quality-assurance-program-manual-describing-the-sellers-quality-capability-and-general-approach-to-quality-assurance.-the-manual-is-subject-to-customers-review-and-acceptance-prior-to-contract-award. .unnumbered}

## Control of Special Processes

## Subcontractor shall use trained and qualified personnel and qualified written procedures in accordance with specified requirements for the performance of certain special processes, including but not limited to, soldering, electronic assembly, brazing, welding, plating, heat treatment, nondestructive examination, etc. {#subcontractor-shall-use-trained-and-qualified-personnel-and-qualified-written-procedures-in-accordance-with-specified-requirements-for-the-performance-of-certain-special-processes-including-but-not-limited-to-soldering-electronic-assembly-brazing-welding-plating-heat-treatment-nondestructive-examination-etc. .unnumbered}

## Design Reviews and Notification of Princeton for Design Reviews 

> PPPL may elect to require that a design review be conducted prior to
> release for fabrication, depending on the extent to which the subject
> equipment is a departure from Seller's standard practice and product
> line. Design review requirements shall be established prior to
> contract award.

## During fabrication any changes in the design shall be documented and the changes shall be submitted to PPPL for approval prior to implementation.

## The Seller shall furnish a biweekly progress report on the job along with the schedule to complete.

## Acceptance Tests 

## Acceptance Test procedures shall be developed by the Seller and approved by PPPL. List of Acceptance Tests to be supplied with Seller's Technical Proposal. All test data shall be furnished to PPPL after completion of the tests and prior to shipment of equipment for delivery. {#acceptance-test-procedures-shall-be-developed-by-the-seller-and-approved-by-pppl.-list-of-acceptance-tests-to-be-supplied-with-sellers-technical-proposal.-all-test-data-shall-be-furnished-to-pppl-after-completion-of-the-tests-and-prior-to-shipment-of-equipment-for-delivery. .unnumbered}

## Submittal of As Built Configuration

##  Seller shall submit drawings and parts lists which describe the as‑built configuration the SPA. The listing may be defined by drawing and revision numbers, unique parts lists or other means of positive identification. Any discrepancy or nonconformance reports shall be part of this configuration documentation package. {#seller-shall-submit-drawings-and-parts-lists-which-describe-the-asbuilt-configuration-the-spa.-the-listing-may-be-defined-by-drawing-and-revision-numbers-unique-parts-lists-or-other-means-of-positive-identification.-any-discrepancy-or-nonconformance-reports-shall-be-part-of-this-configuration-documentation-package. .unnumbered}

##  {#section-3 .unnumbered}

## Handling, Packaging, Shipping, and Storage

## Seller shall control items during handling and shipping and while in storage, including customer furnished items, and shall assure that materials and items are adequately protected from damage or deterioration, with special attention to packaging for shipment. {#seller-shall-control-items-during-handling-and-shipping-and-while-in-storage-including-customer-furnished-items-and-shall-assure-that-materials-and-items-are-adequately-protected-from-damage-or-deterioration-with-special-attention-to-packaging-for-shipment. .unnumbered}

## Customer Receiving/Inspection

## Customer will perform Receiving Inspection on items supplied by the Seller. Discrepant items will be rejected and returned to the Seller or reworked by customer. Costs caused by rejects will be charged to the Seller.  {#customer-will-perform-receiving-inspection-on-items-supplied-by-the-seller.-discrepant-items-will-be-rejected-and-returned-to-the-seller-or-reworked-by-customer.-costs-caused-by-rejects-will-be-charged-to-the-seller. .unnumbered}

## General Purchase Order Requirements

## Material(s) and/or product(s), including those components, parts, and materials that are permanently installed into systems, sub‑systems, and/or assemblies, etc. furnished under this purchase order/subcontract shall be new and unused. Parts and components that have been rebuilt, refurbished, or modified are specifically prohibited unless approved by PPPL in writing. {#materials-andor-products-including-those-components-parts-and-materials-that-are-permanently-installed-into-systems-subsystems-andor-assemblies-etc.-furnished-under-this-purchase-ordersubcontract-shall-be-new-and-unused.-parts-and-components-that-have-been-rebuilt-refurbished-or-modified-are-specifically-prohibited-unless-approved-by-pppl-in-writing. .unnumbered}

## Subcontractors (Suppliers) found to be supplying any of the following will be reported to the Office of the Inspector General, U.S. Department of Energy: {#subcontractors-suppliers-found-to-be-supplying-any-of-the-following-will-be-reported-to-the-office-of-the-inspector-general-u.s.-department-of-energy .unnumbered}

## Re-manufactured, rebuilt, or used parts represented as new.

## Counterfeit parts (fraudulently labeled or marked with another Seller\'s name).

## Misrepresented parts.

## Subcontractor's Responsibility for Conformance

## Neither PPPL\'s review and/or approval of Seller\'s documents not customer\'s inspection of Seller\'s items or services shall relieve the Seller of responsibility for full compliance with requirements of the purchase order/contract. {#neither-pppls-review-andor-approval-of-sellers-documents-not-customers-inspection-of-sellers-items-or-services-shall-relieve-the-seller-of-responsibility-for-full-compliance-with-requirements-of-the-purchase-ordercontract. .unnumbered}

## Release for Shipment Form

## Seller shall obtain a signed \"Product Quality Certification and Shipping Release\" form to be provided by PPPL\'s Quality Assurance Representative prior to PPPL acceptance of procured items or services for full or partial shipment. PPPL reserves the right to refuse to accept shipment unless accompanied by a signed \"Shipping Release Form\". {#seller-shall-obtain-a-signed-product-quality-certification-and-shipping-release-form-to-be-provided-by-pppls-quality-assurance-representative-prior-to-pppl-acceptance-of-procured-items-or-services-for-full-or-partial-shipment.-pppl-reserves-the-right-to-refuse-to-accept-shipment-unless-accompanied-by-a-signed-shipping-release-form. .unnumbered}

##  {#section-4 .unnumbered}

## Certificate of Compliance

## Seller shall submit a C of C stating that the work performed conforms in every respect to the physical configuration and functional inspection/test requirements. The Seller's Quality Assurance Manager shall sign the C of C. This shall be furnished with the shipping release request.  {#seller-shall-submit-a-c-of-c-stating-that-the-work-performed-conforms-in-every-respect-to-the-physical-configuration-and-functional-inspectiontest-requirements.-the-sellers-quality-assurance-manager-shall-sign-the-c-of-c.-this-shall-be-furnished-with-the-shipping-release-request. .unnumbered}

## Inspections and Test Procedures

## Inspections and tests shall be performed in accordance with written procedures referencing criteria for acceptance or rejection. Three copies of inspection and test reports shall be provided to PPPL along with the shipping release request. No repairs shall be performed without written customer notification and concurrence.  {#inspections-and-tests-shall-be-performed-in-accordance-with-written-procedures-referencing-criteria-for-acceptance-or-rejection.-three-copies-of-inspection-and-test-reports-shall-be-provided-to-pppl-along-with-the-shipping-release-request.-no-repairs-shall-be-performed-without-written-customer-notification-and-concurrence. .unnumbered}

## Calibration of Test and Measuring Equipment

## Tests shall be performed using currently calibrated measuring and test equipment traceable to NIST.  {#tests-shall-be-performed-using-currently-calibrated-measuring-and-test-equipment-traceable-to-nist. .unnumbered}

3.  [SCHEDULE]{.underline}\
    \
    Seller shall include design, fabrication, test and delivery schedule
    with quotation.

4.  [SHIPPING AND HANDLING]{.underline}

> SPA to be shipped FOB destination. Ship to:\
> \
> Princeton Plasma Physics Laboratory

Princeton University, Forrestal Campus

Receiving 3, Princeton, NJ 08543

5.  [WARRANTY]{.underline}\
    \
    Seller is to state their standard warranty at the time of quotation.

6.  [DELIVERABLES]{.underline}

    1.  At time of Quotation

        1.  Technical Proposal

> Technical proposal shall be submitted with quotation. The following
> information shall be included, along with any other supporting
> information to establish that proposed design will conform to
> requirements of this specification.

-   *Simplified circuit schematic*

-   *Recommended DC Link capacitance value*

-   *Control block diagram and description of PWM and scheme*

-   *Description of voltage and current feedback control schemes, along
    with predicted performance*

-   *Description of basic power electronic device (e.g. IGBT) to be
    supplied along with justification for same (voltage and current vs.
    duty, expected junction heating under pulsed load)*

-   *Estimate of harmonic content in load current*

-   *Water cooling requirements as applicable*

-   *Description of local control capability, interlocks, and fault
    detection*

-   *Method of current measurement, including accuracy, filtering, etc*

-   *Cabinet dimensions and weight*

-   *Interior and exterior finish details (color, etc.)*

-   *In-process dielectric, interlock, control, and dummy load tests
    that will be performed*

-   *Acceptance Tests*

#### *Exceptions to this specification, along with justification of same*

1.  QA Manual

2.  Provisions of standard warranty

3.  Schedule

```{=html}
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```
1.  At Design Review (if required)

-   *Schematic diagrams*

```{=html}
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```
-   *Performance calculations (junction temperature, harmonics, fault
    conditions, control loop response, etc.)*

-   *Outline Drawing showing PPPL interface details*

-   *Bills of Material*

-   *Test Plan*

## With Delivery

## Operating Manual (3 hard copies plus electronic files as available) 

## As-built Drawings (3 sets hard copy plus CAD files as available)

## Recommended list of spare parts with price

## Test and Inspection Records

## Product Quality Certification and Shipping Release

## Certificate of Compliance signed by Seller's Quality Assurance Manager