I'm looking to create very simple and cheap test set. Test is maybe a big word. It will be presentation set for arc flash. I wonder if someone did something like this already and maybe can give an advice. Base requirements:
- be able to create open arc or arc in box (obviously)
- must be able to generate at least 4000A current
- probably DC voltage i range of 200 - 1000VDC

So far I have two ideas, both of them are for DC arc flash :
1) DC battery set (classic Acid/gel type) + charger + DC protection + lab type switch to control timing (I saw it few times in labs but need to find more details)
2) DC motor + DC protection + lab type switch

Option 1
sounds easy as far I see I will need to balance battery size with voltage and amount of strings to have proper short circuit for specific arc gap ( so it is able to sustain arc and have enough power). Not sure about cost and how much tests I can do with such combination.
Pros:
- no grid connection (so no issues during tests)
Cons
- battery costs
- heavy
- lifetime (4-7 years ) not sure what will happen with batteries after multiple short circuits tests

Option 2
I think about two ways. One is to start and spin motor (DC because it should sustain arc easier) and once ready short circuit it like during normal box test with small wire. This requires a bit of control between lab switch timer with motor supply as it needs to happen at the same time so we don't loose kinetic energy. Preferably motor should spin flywheel like DRUPS
Pros:
- relatively simple
- no lifetime degradation issue (except increased overheating but it should withstand more than battery set up)
Cons:
- Not much data but I think such DC motor will need to be big to get SC 4000A @400V so not practical nor cheap

Option 2A AC motor but fast check and It looks like for 4000A gives me initial size of 315kW (Ir~600A) so this is huge amount


What do you think?