ICEC The 27 th International Conference on Electrical Contacts. presented by Peter Meckler

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1 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 1

2 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 2

3 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 CO 2 emission for so called Net- Zero-Energy Building goal of European Union, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 3

4 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 4

5 Consortium, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 5

6 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 6

7 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 7

8 Objectives Future -7% cost for solar electricity -5% power consumption Today, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 8

9 Objectives Idea of a Retail Market demonstrator (not realized during this period of project) More information about the project see: June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 9

10 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 10

11 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 1. n.. N Control signals HMI 1) Signalaquisition Signalprocessing Actuator Switching element Energy Status Signals 1.m.. M Energy storage Energy LOAD 1) HMI Human Machine Interface, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 11

12 The 27th International Conference on Electrical Contacts 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), June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 12

13 3. DC Switching with Electronic Elements I ()!"#$% ) I I!"#$% V Knee 0.7V V V Knee 0.7V V &' V 1) IGBT Insulated Gate Bipolar Transistor 2) MOSFET Metal Oxide Semiconductor Field-Effect Transistor 3) V Knee Threshold Voltage of pn-junction, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 13

14 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., June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 14

15 4. Hybrid Switch Working Principle 1. Based on three mechanical contact systems (S 1, S 2 and S 3 ) 2. Electronic switching element in parallel to one of the mechanical switches (S 1 ) 3. Electronic part is de-energized in ON-state (S 1 closed) 4. The arising arc during turn OFF causes an arc voltage of 15 20V, which supplies electronics with energy 5. The current commutates from S 1 to IGBT 6. The arc extinguishes immediately 7. The IGBT changes over to the locking state 8. S1 opens up arcless 9. S 2 and S 3 follow with delay and provide physical isolation, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 15

16 4. Hybrid Switch Shutdown cycle U C i Suppy voltage U d Voltage drop U C at S 1 Current i T 1 contact S 1 opens T 2 current commutates to semiconductor T 3 IGBT shutdown T 4 current zero T 1 arcing time 700s T 2 T 3 T 4 T 2 -T 1 arcing time 700s T 3 -T 2 delay time 2ms T 4 -T 3 shut OFF time IGBT 150s T 4 -T 1 shutdown time complete 2.9ms, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 16

17 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), June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 17

18 5. Hybrid Circuit Breaker Electronic Part 160 A IGBT 1) 400 V (DC) Control voltage triggers the MOSFET Gate of the IGBT is activated via constant voltage source (Z 1 ) Z 1 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 control electronic MOSFET 1) IGBT Insulated Gate Bipolar Transistor, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 18

19 5. Hybrid Circuit Breaker Electronic Part Hybrid switch demonstrator - electronic part (under evaluation), June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 19

20 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 20

21 HCB Measurement Results Evaluation of current splitting in hybrid switch Regarding only S 1 (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 = ms, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 21

22 HCB Measurement Results Following variables are measured: Voltage drop at contact U (V) Current IGBT I IGBT (A CH2 ) Current IGBT + varistor I IGVAR (A CH3 ) Current mechanical contact I CON (A CH4 ) I IGVAR I IGBT I CON, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 22

23 HCB Measurement Results Complete shut down cycle mechanical contacts open, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 23

24 HCB Measurement Results 40s Current commutates to semiconductor, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 24

25 HCB Measurement Results delay time 1.2 ms Complete shut down cycle Semiconductor becomes nonconductive, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 25

26 HCB Measurement Results 55s Electronic shut down, varistor begins to work because of overvoltage (minor inductivity in load resistors), June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 26

27 HCB Measurement Results 515s Electronic shut down, varistor works because of overvoltage (inductive load), June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 27

28 HBC Measurements Summary T C /s T S /s τ / ms, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 28

29 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, June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 29

30 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), June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 30

31 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 DC Components and Grid )., June, Dresden, Peter Meckler E-T-A Elektrotechnische Apparate GmbH 31

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