Download Functional Specification - EDMS

TE-EPC-LPC
Low Power Converters
A section from CERN Power Converter Group
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Name first Name
Equipment Code
EDMS Document No.
Equip. Code
1518189
Document Revision: 1.0 (Draft)
Last Revision Date: 2015-07-02
Functional Specification
DOCUMENT TITLE
Abstract
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Author(s) / Involved Person*(s) :
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History of Changes
Rev. No.
Date
1.0
2015-xx-xx
Pages
Description of Changes
Document creation
* Attending meeting in case of minute reporting.
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Document Title
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EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
Table of Contents
1.
1.1
Introduction ............................................................................................3
BI.BVT upgrade overview ............................................................................ 3
2.
2.1
2.2
Circuit requirements................................................................................4
Operating mode requirements...................................................................... 4
Electrical requirements................................................................................ 4
3.
Operating condition requirements ...........................................................5
4.
4.1
4.2
Powering solution ...................................................................................6
Converter .................................................................................................. 6
Patch Panel ............................................................................................... 9
5.
Conclusion .............................................................................................10
6.
6.1
6.2
6.3
Annexes ................................................................................................11
Possible location in Booster ....................................................................... 11
Possible cooling distribution ....................................................................... 11
Possible arrangement in Booster ................................................................ 12
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EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
1. Introduction
The vertical bending magnet BI.BVT corrects the deflection immediately after BI.SMV to
a horizontal trajectory towards the PSB Injection section.
1.1 BI.BVT upgrade overview
1.1.1 BI.BVT current system description
The BI-BVT10 vertical dipole magnet is a window framed D.C. magnet with four
apertures, which has been powered by a single power converter. It is positioned after
the Booster Injection distributer (BI.DIS) and septum (BI.SMV) to deflect three of the
beams (One passes through without deflection) into the path of the 4 super imposed
Booster rings.
Fig. 1: BI.BVT Magnet and its current – 2015 – single power converter
1.1.2 Reason for upgrade
This document EDMS N° 1188530 v.1.0 “The modifications of the BI.BVT10 vertical
dipole magnet in the booster injection line for operation with the LINAC 4” explains the
reason for a new powering system. The main parameters impacting the powering
system can be summarized as below:

Operation still requires DC-only powering system.

Output current in magnet coils is increased from  230A to  420 A.

A dedicated power converter is now required for each magnet coils.
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EDMS N°: 1518189
Document Title
Rev. : 1.0 (Draft) / Date: 2015-07-02
2. Circuit requirements
The circuit is, per definition, the load applied to the Power Converter, viewed from its
output connexion points: the magnet series its “DC” cable. Three circuits are
considered and named: [BI1.BVT, BI2.BVT, BI4.BVT] corresponding to the BI-BVT10
vertical magnet coils referred to each circulating beam. This document summarizes only
the requirements which impact the converter choice.
2.1 Operating mode requirements
DC Mode is considered only in the actual proposal, with a current reference being sent
to the converter and being kept constant for hours, without any need to cycle around
this DC value, with reference change for adjusting the DC current reference.
Several hours
I.op
[A]
[0;10] Hz freq.
Ref change
Several hours
t [s]
Fig 2: Typical cycle taken as operational reference
2.2 Electrical requirements
Parameter
Unit
BI1.BVT
BI2.BVT
BI4.BVT
Magnet Inductance
[H]
0.0122
0.0095
0.0095
Magnet Resistance @ 20°C coil temperature
[Ohms]
0.056
0.046
0.046
Maximum operating current (Iop.max)
[A]
418.2
414.5
414.5
Minimum operating current (Iop.min)
[A]
0
Maximum ramping Time, from Iop.min to Iop.max.
[s]
4
Magnet applied common mode from operation
configuration
[V]
None *
*Magnet is not polarized vs ground by an
external system.
“rms stability of 100 ppm”
(gaussian distribution based)
Required precision level given by operation
Deduced individual circuit values, placed in perspective of the powering proposal
DC voltage being applied to magnet only
(dI / dt = 0) @ 20°C coil temperature
[V]
Maximum cable drop voltage available between Patch
Panel Rack - see after - and Magnet (from data above)
[V]
Regulated current rate
[A/s]
 100
Maximum magnet energy stored (from above)
[kJ]
1.06
Maximum current variation*
- Over a week
- [0; 5] °C max ambient T°C change
* all effects including, from slow phenomena (T°C,
drifts…), medium frequency (regulation loop error), up
to higher frequency noise (converter voltage ripple
inducing current ripple in the load)
23.4
19.1
10
14
19.1
6 V corresponds to 2 x 100 m of 240 mm²
cable, 100 m go and return, @ Iop.max
0.83
84 *
[mApk-pk]
* Standard deviation of expected operating
current variation = 100 ppm. Other said,
95 % of the delivered current
measurements are in 2 x 100 ppm of 420
A window, i.e. 84 mApk-pk
Table 1: Circuits overview
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Document Title
EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
3. Operating condition requirements
3.1.1 Interlock system level & monitored parameters required by operation
The table below is to be applied to each circuit, and then to each power converter since
one circuit equals one converter.
Item
Required
Comments
WIC
(Warm Interlock
Controller)
Yes
Each circuit is assumed to be individually protected, with
three interlock cables arriving to the powering system
proposed.
BIS
(Beam Interlock
System)
No
SIS
(Software Interlock
System)
Yes
EIS
(Equipt Important
for Safety)
No
Oasis
Yes
Converter analogue data & states available through FGC3
published data only.
Acquisition
Yes
Converter analogue data & states available through FGC3
published data only.
Converter analogue data & states available through FGC3
published data only.
Table 2: Interlock system and monitored parameters required by operation
3.1.2 Circuit protection requirements
The machine requirements protection system are displayed below; these protection are
dedicated to the circuit (magnet + cable) only.
Level
Required
Comments
Over V
Not formally
required
Over I
Not formally
required
WIC system will monitor the operating parameters of each
magnet, and will detect if abnormal conditions rise, coming
from too high magnet current or cooling issues (water
flowrate), as long as current delivered by power converter is
less than ±660 A.
Earthing leakage
detection
Not formally
required
Standard protection being provided by power converter is
accepted as a valid solution.
Magnet Ej
Discharge
Not formally
required
Converter can dissipate the maximum energy stored in the
circuit with no impact for operation, if kept in its maximum
operating limits.
Table 3: Circuit protection levels / functionalities required by operation
At the exception of earthing protection, which is applied to the whole output circuit of
the power converter, i.e.: the power converter output stage, the cable and the magnet,
no active protection is foreseen at the level of the DC cable. This cable can be passively
protected, taken into account the maximum output current the power converter can
deliver, i.e. 600 A.
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Document Title
EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
4. Powering solution
The proposed solution is based on
 Four Power Converters (four Power Racks), (three + one live spare).
 One Patch Panel (one Rack) to quickly re-arrange the DC connexion cables to
switch from any faulty converter to the live spare one, with its interlock cable. FGC
Controller is assigned to the new circuit thanks to a dongle plugged into FGC in use.
2
Converter N°1
Operational
Converter N°2
Operational
1
4
1
AC
Interlock Mains
Cooling
(Water +Air)
Interlock
FGCEther
+
BI2.BVT
dongle
2
1
2
3
3
AC
Mains
Cooling
BI1.BVT
BI2.BVT
Interlock
BI4.BVT
AC
Interlock Mains
Cooling
(Water +Air)
BI1.BVT (WIC)
Cabling « internal » to powering solution
Converter N°4
Live Spare
3
2
AC
Mains
(Water +Air)
FGCEther
+
BI1.BVT
dongle
Converter N°3
Operational
Patch Panel
1
AC
Mains
Cooling
3
Interlock
BI2.BVT (WIC)
Interlock
BI4.BVT (WIC)
FGCEther
+
BI4.BVT
dongle
Interlock
(Water +Air)
FGCEther
Fig. 3: Overview of the powering proposal
4.1 Converter
Each BIx.BVT circuit will be powered by a LHC600A-40V converter type, a power
converter described here and being designed and initially produced for LHC machine,.
4.1.1 Converter Main performance
Parameter
Data – Comments
Output Current Range
±600 A
Output Voltage Range
±40 V
Operating Power Range
[0; 24] kW continuous, with a given capability to absorb
load energy, not used in this case.
Maximum current variation*
- Over a week
- [0; 5] °C max ambient T°C change
* all effects including, from slow
phenomena (T°C, drifts…), medium
frequency (regulation loop error), up
to higher frequency noise (converter
voltage ripple inducing current ripple in
the load)
60 mApk-pk
Operation mode
Regulated DC-mode
Bandwidth I | V
IFGC: [1; 50] Hz | VPWR SOURCE: 700 Hz
Voltage output noise
8 mVrms max. for each frequency in @ [50Hz; 20MHz]
Current output noise
Depending on the Load (magnet) raw parameters (R.circuit,
L.magnet). In this case, the total output current noise in [50
Hz; 20 MHz] is less than 10 mArms.
Topology | Efficiency
4 Quadrant, 25 kHz switching mode | 83 % @ [420 A; 25 V]
1 ppm of 600 A = 0.6 mA; the converter is a 30 ppm (18
mA) accuracy system over 1 year. Additionnaly, voltage
Ripple @ 300 Hz < 8 mVrms will induce Inoise.max @ 300
Hz expected  2 mArms based on: Lmagnet.300 Hz > 0.5 x
Lmagnet.DC .
Table 4: Power Converter main performance data
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EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
4.1.2 Converter Main functionalities
Functionality
Earth leakage
current detection
Description
This system is based on a two modes detection system: Active (converter OFF)
and Passive (converter ON).
In Active mode, when converter is OFF-state only, the load is polarized in
common mode to +10 V versus earth on its negative output connexion point.
This allows to detect any earthing leakage faulty condition, without the need to
energise the circuit for allowing the detection system to operate.
In Passive mode, when converter is ON-state only, a 10 Ohms earthing resistor
series a 1A fuse connects the negative polarity to earth, with this resistance
being used as a current sensor (shunt) sensing the circuit earthing leakage
current.
The system monitors the earthing leakage current to a value of ±50 mA
maximum allowed. The fuse (1 A – fast) is provided to limit damage risk on the
circuit side in any case and any earthing system operating mode (active or
passive)
I hardware
limitation
(output current
limit)
Discharge crowbar
The converter can be protected on the Power Source directly (not involving the
FGC controller, nor the DCCTs). The setting range is 5-steps only predefined
limits: [±88, ±132, ±330, ±550, ±660] A.
Note: A more flexible limitation level can be set using FGC Controller and its
two DCCTs sensors measuring the output current.
A crowbar system, integrated in the rack, limits the voltage across the magnet
thanks to a resistor of 0.05 Ohms, which collects the magnet current in case of
a fault, which results in the output stage of the converter to become nonconductive. The crowbar can dissipates a maximum energy of 108 kJ stored in
the circuit.
Table 5: Power Converter main functionalities
4.1.3 Converter Control/Signal Interfaces
Every cable is intended to be connected one to one, with the adequate end connector at
the level of the power converter with 360° shielded metallic connectors.
Interfaces
Comments – Location
FGC-Ether
FGC3 field bus. (Converter control, timing, etc…).
RJ-45 shielded connector plugged directly on FGC3 K7, top-front rack location.
SKINTLK
Compatible PIC & WIC. (Fast-Abort, Ppermit & Powering Failure signals).
12-pin female chassis burndy connector located at the bottom of the rack.
Important note: The interlock cables from WIC system are not intended to be
connected directly to the Power Converter Rack, but to the Patch Panel Rack,
which will manage the dispatch of the WIC cables to relevant Power Converter
referred to its circuit being connected.
SKPARE
User/Spare interlock purpose. (Not to be used in this case.)
4-pin male burndy chassis connector located on lower Power Module.
Table 6: Power Converter interfaces data
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EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
4.1.4 Converter Controller & Measurement
Item
Data - Value - Comments
Controller
FGC3 (using SKCMD +SKDIAG LHC-designed standard interfaces, through Cobalt
Chassis, compatible FGC3  LHC power source)
Measurement
2x DCCTs [MACC2+ 600 A ] + I2V card.
Table 7: Power Converter controller & measurement
4.1.5 Converter Power Interfaces
All power interfaces cables are intended to be connected one to one, with the adequate
end connector at the level of the power converter.
Item
AC
connexion
Data - Value - Comments (*: recommended values)
Individual AC connexion on each of the four Power Converter Racks is required, with a
dedicated AC protected departure for each. They shall not include differential protection.
Rack Front bottom | AC Cable cross-section compatibility: [6; 10] mm²
Individual departure 3P+N+PE current rating:
- 45 Amin  Pout = 24 kW (converter output power: 40 V x 600 A)
- 35 Amin  Pout = 18 kW (converter output power: 40 V x 450 A )
Note: a 5x10mm² cable is normally considered for this converter type in other
machines.
DC
connexion
Rack Top Front | Rack DC busbar hole diam. D:16.8 mm | DC cable cross-section: up to
3x 240 mm² per polarity.
Important Note: The cable magnets are not intended to be connected directly to the
Power Converter Rack, but to the Patch Panel Rack. A DC connexion will be put in place
between Power Converter Rack and Patch Panel Rack.
Cooling
Water-Cooled (+air) | Bottom connexion, under rack | Parker connectors.
- Max absolute pressure on water converter circuit: 16 bars
- Max inlet water temperature allowed:
25 °C
- Individual power rack nominal settings:
5 l/min @ 4 bars*
* differential pressure drop measured on rack Parker connectors.
Power losses in water cooling system and air:
- 5.0 kWatts in water  Pout = 24 kW (converter output power: 40 V x 600 A)
- 3.5 kWatts in water  Pout = 18 kW (converter output power: 40 V x 450 A )
- 600 Watts in air whatever Pout is.
Important note: power converter water applied conditions must be adjustable to work
as close as possible to nominal data given above. If the four racks (three operation +
one live spare) are considered to share the same inlet common pipe, great care shall be
taken to the pressure drop along the pipe.
Table 8: Power Converter power interfaces
4.1.6 Converter Rack Installation
Item
Data - Value - Comments (*: recommended values)
Power rack
(not filled
with power
modules)
205 cm x 60 cm x 90 cm | 200 kg | Racks back to back possible (need from rear side is
not mandatory).
Rack
Installation
Rack are ideally located on metallic supporting beams, increasing the accessibility to the
power connexions (AC and water).
The four Power Converter Racks are ideally placed side to side and side to Patch Panel
Rack, which can be located at the centre or not of the power converter racks, for simple
system overall architecture.
Table 9: Power Converter Rack installation
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Document Title
EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
4.2 Patch Panel
The Patch Panel Rack collects:
 The three sets of “DC” power cables from BI.BVT magnet
 The three sets of interlock cables from WIC system
It redirects these power and signal connexions to three over the four converters
available. The Patch Panel Rack is a new design specifically dedicated to this case.
4.2.1 Patch Panel Power Interfaces
Item
Data - Value - Comments (*: recommended values)
Patch Panel Rack
AC connexion
AC connexion on Patch Panel is required, with a dedicated AC
protected departure. It shall not include differential protection.
Rack Front bottom | AC Cable cross-section compatibility: [2.5*; 10]
mm² | departure 3P+N+PE ratings: 10 Amin
Patch Panel Power Converter
DC connexion (collecting the
4x converters cables)
Rack Top | Rack DC busbar hole diam. D:16.8 mm | DC cable crosssection: [240*; 400] mm² per polarity.
Patch Panel Machine Circuits
DC connexion (collecting the
3x magnet DC power cables)
Rack Bottom Front | Rack DC busbar hole diam. D:16.8 mm | DC
cable cross-section: [240; 400] mm² per polarity.
Power Rack
Cooling connexion
Air | Max power losses: 1 kWatts in total, with all three BIx.BVT
powered at 420 A.
Maximum voltage drop allowed for the final sizing of these power
cables can be found in the electrical parameters table.
Table 10: Patch Panel power interfaces
4.2.1 Patch Panel Control/Signal Interfaces
Every cable is intended to be connected one to one, with the adequate end connector at
the level of the power converter with 360° shielded metallic connectors.
Interfaces
Comments - Location
SKINTLK
(collecting the 3x interlock
cables protecting magnets)
Compatible PIC & WIC. (Fast-Abort, Ppermit & Powering Failure
signals). 12-pin female chassis burndy connector located at the
bottom of the rack.
Table 11: Patch Panel interfaces data
4.2.2 Patch Panel Rack Installation
Item
Data - Value - Comments
Patch Panel Rack
205 cm x 60 cm x 90 cm | 200 kg | Rack back to back possible (need
from rear side is not mandatory).
Rack Installation
Rack is ideally located on metallic supporting beams, increasing the
accessibility to the power connexions (AC, DC, Interlock).
The Patch Panel Rack should be ideally placed side by side with the
four Power Converter Racks.
Table 12: Patch Panel installation data
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Project ID
Document Title
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EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
5. Conclusion
The powering system described is based on known and existing power converter type
being intensively used for LHC machine. The performances of the converter are wellknown, and its reliability is proved.
By the addition of a Patch Panel, the proposed solution allows very fast intervention in
case of a faulty element in one operational converter.
Some possible implantations of the overall system are presented – for info - in
following annexes, based on systems already designed in LHC.
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EDMS N°: 1518189
Rev. : 1.0 (Draft) / Date: 2015-07-02
6. Annexes
6.1 Possible location in Booster
Fig. 4: Possible location of the five required racks
6.2 Possible cooling distribution
This type of converter was already installed in the LHC, and in the batch of four
converters being placed side by side. The figure below presents the chosen solution
regarding the water distribution.
Trimming
Valve
Tap
Water In
Open/Close
Water Out
Tap
Open/Close
Rack
N°1
Rack
N°2
Rack
N°3
Rack
N°4
Fig. 5: Possible water layout (copy of LHC solution)
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6.3 Possible arrangement in Booster
Tray to be added
Control
(FGCEther)
Converter 4
Pwr Rack 1
DC Outputs
Control
(FGCEther)
Dongle Converter 3
BI4.BVT
Pwr Rack 2
DC Outputs
SK-LEAD
Pwr Rack 3
DC Outputs
SK-LEAD
DCCT
A
SK-LEAD
DCCT
A
Dongle Converter 2
BI2.BVT
Over-I Trim
Earth Fuse
V.neg / ear th
I.out
DCCT
B
Over-I Trim
Over-I Trim
Eq. Stop
V.out
V.neg / ear th
Earth Fuse
Eq. Stop
V.neg / ear th
V.out
Earth Fuse
V.out
I.out
V.out
Control
(FGCEther)
Dongle Converter 1
BI1.BVT
DCCT
B
Earth Fuse
Eq. Stop
V.out
DCCT
A
DCCT
B
Over-I Trim
Eq. Stop
V.neg / ear th
SK-LEAD
DCCT
A
DCCT
B
Control
(FGCEther)
Pwr Rack 4
DC Outputs
I.out
I.out
V.out
V.out
V.out
00 -04 -08 -12 -16 -20 -24 -28 -32 -36 -40 -44 -48 -52 -56 -60 -64 -68 -72 -76 -80 -84
P
S
U
1.1
1.1
8TE
6TE
10TE
I2V FGC3
1U
00 -04 -08 -12 -16 -20 -24 -28 -32 -36 -40 -44 -48 -52 -56 -60 -64 -68 -72 -76 -80 -84
P
S
U
1.1
1.1
8TE
6TE
10TE
00 -04 -08 -12 -16 -20 -24 -28 -32 -36 -40 -44 -48 -52 -56 -60 -64 -68 -72 -76 -80 -84
I2V FGC3
P
S
U
1.1
1.1
8TE
6TE
10TE
I2V FGC3
00 -04 -08 -12 -16 -20 -24 -28 -32 -36 -40 -44 -48 -52 -56 -60 -64 -68 -72 -76 -80 -84
P
S
U
1.1
1.1
8TE
6TE
10TE
I2V FGC3
Patch Panel
Rack
LHC600A-40V SUB-MOD. 2
LHC600A-40V SUB-MOD. 2
0000
0000
0000
0000
LHC600A-40V SUB-MOD. 1
12p
LHC600A-40V SUB-MOD. 2
LHC600A-40V SUB-MOD. 1
4p
12p
AC-Plug
0000
0000
0000
0000
LHC600A-40V SUB-MOD. 1
4p
12p
AC-Plug
4p
AC-Plug
12p
AC-Mains
Pwr Rack 1
LHC600A-40V SUB-MOD. 2
12p
12p
12p
Water
Outlet
4p
AC-Plug
Water
Inlet
Common water
Distribution pipe to be
added
AC-Mains
Patch
Panel Rack
AC-Mains
Pwr Rack 2
Interlock
(PIC/WIC)
Cable
LHC600A-40V SUB-MOD. 1
AC-Mains
Pwr Rack 3
AC-Mains
Pwr Rack 4
Beam to be added
Interlock
(WIC)
BI1.BVT
DC-Cables
BI1.BVT
Interlock
(WIC)
BI2.BVT
DC-Cables
BI2.BVT
Interlock
(WIC)
BI4.BVT
DC-Cables
BI4.BVT
Fig. 6: Overview of the powering proposal
The solution is presented in the following configuration relying on:

A common water pipe path (installed by water services (EN-CV), with adequate
connectors distributed along the pipes), on which all converters are connected to.

The racks located on metallic beams for an easy services access (AC, DC, water).

WIC cables being arranged (length) so that they can be switched between Power
Racks for the live spare configuration different cases.

Please note that the Patch Panel Rack could be placed adequately at any place, on
left, right or middle position in the row.
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