The 27th International Conference on Electrical Contacts
ICEC 2014
Authors:
Peter Meckler, E-T-A Elektrotechnische Apparate GmbH, Altdorf, Germany
Frank Gerdinand, E-T-A Elektrotechnische Apparate GmbH, Altdorf, Germany
Roland Weiss, Siemens AG, Erlangen, Germany
Ulrich Boeke, Philips Group Innovation – Research, Eindhoven, Netherlands
Anton Mauder, Infineon Technologies AG, Neubiberg, Germany
presented by Peter Meckler
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
© E-T-A Elektrotechnische Apparate GmbH
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The 27th International Conference on Electrical Contacts
ICEC 2014
Content
1. Project Issue
• Introduction (DCC+G Project)
• Key figures
• Consortium
• Rationale
• Objectives
2. Electric Protective Devices
3. DC Switching with Electronic Elements
4. Hybrid Switch (HS)
5. Hybrid Circuit Breaker (HCB)
• Mechanical Part
• Electronic Part
• HCB Prototype
• HCB Measurement Results
6. Conclusion / Outlook – Next Steps
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
1. Project issues DCC+G
Introduction
•
•
•
•
Joint undertaking “Direct Current Components and Grid (DCC+G)”
European funded Project
Using Direct Current (DC) grids of +/- 380 V for commercial building
Major consumers operate with DC like lighting, cooling, air
conditioning, information technology
• Local energy sources (PV, wind, fuel cell) operate with DC
• Reduce energy consumption and CO2 emission for so called “NetZero-Energy Building” goal of European Union
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Key Figures
• Total budget of 18.4 million € (cost) and 8.8 million € funding
• Duration 36month
• 12 partners from 5 countries (5 small and medium enterprises
(SME), 4 Industry partners (IND), 3 research institutes (HE)
• One task is the evaluation of a DC hybrid switch for 380 V grids
Effort share of the organisation types
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Consortium
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Rationale
• Today we use AC to distribute electric energy in
buildings
• More then a century ago only transformers
offered the possibility to change voltage levels
with high efficiency
• Due to the good availability of semiconductor
switches DC/DC converters offer today the
possibility to change voltage levels with high
efficiency
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Objectives
• Develop and demonstrate DC power grid technology
as a standard for future energy-efficient building
• The main focus of the DCC+G project is R&D on
semiconductor technologies, DC power components,
system modules and the validation of more energy
efficiency
• 5% reduction of power consumption
• 7% reduction of cost for solar electricity
• Retail demonstrator (will not be realized during this
period)
• Office demonstrator (FhG IISB, Erlangen)
• Focus of this presentation is the evaluation of a
safety switch in hybrid technology
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Objectives
Future
-7% cost for solar
electricity
-5% power
consumption
Today
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Objectives
Idea of a Retail Market demonstrator (not realized during this period of project)
More information about the project see: http://www.dcc-g.eu
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Objectives: WP2 Protective Device
Develop contactor and circuit breaker for +/- 380 VDC grids with
rated currents up to 250 A
Concepts realized:
1. Mechanical: Bidirectional contactor up to nominal current of 250 A
(see Poster Poster P12.10, R. Pimenta, L. Hofmeister: Optimising the magnetic field system of a
high voltage relay without protective gas)
2. Hybrid Circuit Breaker rated current 5 A to 160 A
• 160 A circuit breaker
• IGBT switch for 160 A
• Combine both technologies for a hybrid demonstrator
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
2. Electric Protective Devices
•There are 6 major components of an Electric Protective Device.
•HYBRID-technology will be the future of switching elements
providing fast switching, no arc, low ON-state losses!
GRID / LINE
Control
signals
Signalaquisition
Status
Signals
Signalprocessing
1….m..M
HMI1)
Actuator
Energy
storage
Switching
element
Energy
Energy
1…. n.. N
LOAD
1) HMI Human Machine Interface
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
3. DC Switching with Electronic Elements
•
•
•
•
Either MOSFETs or IGBTs are best choice for DC switching
Minimum blocking voltage should be 600V for 380V DC grids (transients!)
MOSFETs are best choice for applications requiring least losses
IGBTs are best choice for higher blocking voltages (> 1kV) , e.g. in hybrid
switches
IGBT opened up (TO-252 housing)
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
3. DC Switching with Electronic Elements
()
I
⋅
!"#$%
VKnee 0.7V
1)
2)
3)
I
I
IGBT
MOSFET
VKnee
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)
V
VKnee 0.7V
V
↓
&'
V
Insulated Gate Bipolar Transistor
Metal–Oxide–Semiconductor Field-Effect Transistor
Threshold Voltage of pn-Junction
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
4. Hybrid Switch
Classic Conception
• Semiconductor switches have many advantages
such as the frequency of operation and the quick
current quenching.
• Disadvantages include power losses, missing
isolation function and EMC problems.
• Hybrid switches diminish the mentioned
disadvantages at least partly.
• Semiconductor operates mainly during the
switching function.
• Mechanical contact takes over current flow in ON
position.
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
© E-T-A Elektrotechnische Apparate GmbH
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The 27th International Conference on Electrical Contacts
ICEC 2014
4. Hybrid Switch
Working Principle
1.
2.
3.
4.
5.
6.
7.
8.
9.
Based on three mechanical contact systems (S1, S2 and S3)
Electronic switching element in parallel to one of the mechanical
switches (S1)
Electronic part is de-energized in ON-state (S1 closed)
The arising arc during turn OFF causes an arc voltage of 15…20V,
which supplies electronics with energy
The current commutates from S1 to
IGBT
The arc extinguishes immediately
The IGBT changes over to the
locking state
S1 opens up “arcless”
S2 and S3 follow with delay and
provide physical isolation
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
UC
ICEC 2014
4. Hybrid Switch
Shutdown cycle
i
Suppy voltage Ud
Voltage drop UC at S1
Current i
T1 contact S1 opens
T2 current commutates
to semiconductor
T3 IGBT shutdown
T4 current zero
arcing time 700 s
T1
T2
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
T3 T4
© E-T-A Elektrotechnische Apparate GmbH
T2-T1 arcing time 700 s
T3-T2 delay time 2ms
T4-T3 shut OFF time
IGBT 150 s
T4-T1 shutdown time
complete 2.9ms
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The 27th International Conference on Electrical Contacts
ICEC 2014
5. Hybrid Circuit Breaker
Mechanical Part
Hydraulic-Magnetic Circuit Breaker
•voltage rating 380 V DC, 3 poles in series
•current rating range: 5 A … 160 A
•fast remote trip module (coil)
•remote ON/OFF function (motor drive)
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
5. Hybrid Circuit Breaker
Electronic Part
160 A IGBT1)
400 V (DC)
•Control voltage triggers the MOSFET
Z1
•Gate of the IGBT is activated via constant
voltage source (Z1)
R
IGBT
•The total current is conducted over the
electronic switching element
•To lock the switching device, the control
electronic disconnects the MOSFET
•The IGBT and the MOSFET lock
•Current flow is nearly zero and the OFF-state
is re-established
MOSFET
control
electronic
1) IGBT Insulated Gate Bipolar Transistor
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
© E-T-A Elektrotechnische Apparate GmbH
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The 27th International Conference on Electrical Contacts
ICEC 2014
5. Hybrid Circuit Breaker
Electronic Part
Hybrid switch demonstrator - electronic part (under evaluation)
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
5. Hybrid Circuit Breaker (HCB)
Prototype
HCB demonstrator (first prototype)
130 mm
Hydraulic-magnetic circuit
breaker
plus fast remote trip and
remote ON / OFF
IGBT
plus electronic control circuit
90 mm
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
Evaluation of current splitting in hybrid switch
• Regarding only S1 (main contact of circuit breaker) and semiconductor
• Voltage rating: 380 V DC
• Current rating range: 40A … 160 A
• Inductivity tested up to a time constant of τ = 1 ... 3 ms
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
• Following variables are measured:
• Voltage drop at contact U
(V)
• Current IGBT IIGBT
(ACH2)
• Current IGBT + varistor IIGVAR
(ACH3)
• Current mechanical contact ICON (ACH4)
IIGVAR
IIGBT
ICON
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
Complete shut down cycle
mechanical contacts open
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
Current commutates to
semiconductor
40 s
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
delay time 1.2 ms
Complete shut down cycle
Semiconductor becomes
nonconductive
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
55 s
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
Electronic shut down, varistor begins
to work because of overvoltage (minor
inductivity in load resistors)
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The 27th International Conference on Electrical Contacts
ICEC 2014
HCB Measurement Results
515 s
Electronic shut down, varistor
works because of overvoltage
(inductive load)
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
HBC Measurements Summary
TC/ s
TS/ s
τ / ms
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
6. Conclusion / Outlook
Hybrid switch prototypes under evaluation
•Good performance of IGBT based prototype
•Tests with CoolMOS™ devices
•Try to reduce complexity in electronic device
•Reducing shut down time
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
6. Conclusion - Next steps
Test of Arc Fault Detection Module (AFDM)
•AFDM performance within a 380V DC grid
•Evaluation of specific system parameters within a DC-grid
•Coupling of AFDM with Hybrid Circuit Breaker (see also Paper „Arc Fault
Detection a Model Based Approach“, C. Strobl)
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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The 27th International Conference on Electrical Contacts
ICEC 2014
Thank you for your attention – Questions?
Peter Meckler
E-T-A GMBH, Altdorf bei Nürnberg, Germany
Acknowledgment
We thank the Bundesministerium für Bildung und Forschung and the
European Community for funding the project
DCC+G (BMBF FKZ 13N12113; ENIAC Nr. 296108 “DC Components and Grid”).
ICEC 2014, 22.-26. June, Dresden, Peter Meckler
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