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ATF2 Project HA Power Supplies Demonstration System Evaluation Criteria And Status as of February 23, 2006 Paul Bellomo and Briant Lam February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 1 Demonstration Criteria Build a power system with Ethernet control that will provide 150A in a 3 out 4 redundant module configuration. Demonstrate performance, redundancy and current sharing February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 2 Rack and Power System Layouts 480V, 3 F 48X 47X 46X 45X 44X 43X 42X 41X 40X 39X 38X 37X 36X 35X 34X 33X 32X 31X 30X 29X 28X 27X 26X 25X 24X 23X 22X 21X 20X 19X 18X 17X 16X 15X 14X 13X 12X 11X 10X 9X 8X 7X 6X 5X 4X 3X 2X 1X 120V, 1 F 480V, 3 F 480V, 3 F AC Distribution Main and 2 – 30A Circuit Breakers AC Distribution Main and 2 – 30A Circuit Breakers Transductors PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller 120V, 1 F 480V, 3 F 480V, 3 F 120V, 1 F AC Distribution Main and 2 – 30A Circuit Breakers AC Distribution Main and 2 – 30A Circuit Breakers AC Distribution Main and 2 – 30A Circuit Breakers Transductors Transductors PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller Spare Controller Spare Controller Transductors PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller S M Quad PS 3kW M Quad PS 3kW M Quad PS 3kW M Quad PS 3kW M Quad PS 3kW M Quad PS 3kW E Quad PS 3kW S E Quad PS 3kW FF Dipole PS 4kW E Quad PS 3kW E Quad PS 3kW FF Dipole PS 4kW E Quad PS 3kW E Quad PS 3kW FF Dipole PS 4kW E Quad PS 3kW E Quad PS 3kW FFSex 1kW FFSex 1kW FFSex 1kW FF Oct 1kW 30V, 400A Bulk Power Supply 30V, 400A Bulk Power Supply February 23, 2006 30V, 400A Bulk Power Supply 30V, 400A Bulk Power Supply S S S FF Sex 1kW FF Sex 1kW FF Oct S 1kW AC Distribution Main and 2 – 30A Circuit Breakers S Transductors PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller Spare Controller S 480V, 3 F S S FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW S S S S Transductors PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller PS Controller Spare Controller S FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW 30V, 400A Bulk Power Supply 30V, 400A Bulk Power Supply 30V, 400A Spare Bulk Power Supply 30V, 400A Bulk Power Supply 30V, 400A Chicane Power Supply 30V, 400A Bulk Power Supply HA Power Supplies - Demonstration Criteria and Status FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW FF Q 1kW Space 30V, 400A Bulk Power Supply 3 System Block Diagram AC Power Global Control Cooling Water Ethernet Controller Reg V Source Note that the demonstration system might not include all the elements shown in this block diagram 4 Power Modules Transductor Power Cables Magnet February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 4 Availability Improvement By Oversizing and Redundancy Power Module PR=1/3PL PO=1/4PL PO=3/4PR Power Module PR=1/3PL PO=1/4PL PO=3/4PR Power Module PR=1/3PL PO=1/4PL PO=3/4PR Power Module PR=1/3PL PO=1/4PL PO=3/4PR Load = PL February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 5 Test Parameters and Success Criteria Evaluated Parameter Success Criteria Rated load current from redundant configuration 150A regulated output from either 4 modules or 3 modules Load current sharing ≤ 5% current mismatch from 3 or 4 modules at 100% and 25% rated output Redundancy Loss of one module, system recovers current within 1 millisecond Current stability versus time and temperature ≤ 3 ppm drift in 10 minutes, monitor DT ≤ 10 ppm drift in 8 hours, monitor DT Bandwidth ≥ 10Hz by Bode plot Ethernet control New Ethernet controller February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 6 Status as February 23, 2006 • Presently operating and evaluating five parallel-connected power modules under closed loop control under BitBus control • Operating with phase-shifted input PWM signals to increase effective switching frequency and reduce output ripple. • Operating to a combined 100A of load current while monitoring individual power module output current and output ripple voltage. Observed nicely balanced currents in the power modules. • Correlated load current sharing to the precision of match among the five phaseshifted PWM signals. • Simulated a failure of one power module by disabling the PWM signal to one power module during five power module operation to 100A,. Observed a redistribution of load current among the remaining four operating power modules. This indicates that the redundancy scheme is feasible. • Confirmed the expected increase in output voltage ripple when one power module is disabled. • The demonstration system is on a correct technical path, it is on budget and it is on schedule February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 7 The System February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 8 Operating Power Supplies February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 9 The Power Modules February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 10 Near-Term Next Steps 1. Operate four power modules in a three-out-of-four redundant configuration connected to an inductive load to provide a combined output of 150A. Upon the loss of one module the remaining three will each operate at their rated output of 50A. Monitor the transient current redistribution among the power modules under these conditions. 2. Place four power modules into an environmentally-controlled temperature chamber (refer to the next slide). Connect them to an inductive load. Test the load current stability and power module current sharing versus time and temperature of the three-out-of-four configuration. 3. Upgrade the BitBus controller to an Ethernet controller February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 11 Environmental Test Chamber February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 12 End Slide - Development Workaround During Decision Period Workaround during decision phase Item 3 critical path – Interface with KEK to specify the controls, performance/features of the power modules and their crates February 23, 2006 HA Power Supplies - Demonstration Criteria and Status 13