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LCLS Injector, Sector 21 and BC1 New Power Supplies Needed for First Injection P. Bellomo March 30, 2006 LCLS Power Supplies 1 Paul Bellomo [email protected] List of Needed Magnet Power Supplies Refer to the list in the binder Intermediate Power Supplies 6 dipole and quadrupole magnets require 8 power supplies 13 on order, 1 contingency of each type MCOR12 Power Modules 72 corrector, quadrupole and trim magnets require 72 power supplies 75 on order, 3 are contingency MCOR30 Power Modules 12 corrector, quadrupole and trim magnets require 12 power supplies 20 on order, 8 contingency MCOR Bulk Power Supplies 3 needed, 3 ordered, 0 contingency March 30, 2006 LCLS Power Supplies 2 Paul Bellomo [email protected] Intermediate Power Supplies March 30, 2006 LCLS Intermediate Power Supplies 3 Paul Bellomo [email protected] Performance Requirements Output V, I and P At least 10% greater than magnet standardize value Short term stability 100 ppm RMS, 1 second, Long term stability 100 ppm RMS, 10 seconds at 30C Stability versus temp 2 ppm / O C – 10 to 100% Ambient 40OF (4 OC) to 113 OF (45 OC) Bandwidth as V source DC to – 3 dB 1,000Hz Bandwidth as I source DC to – 3dB 10Hz Conducted EMC / Life/ MTBF FCC, Part 15, Class A 20 years 100,000 hrs Load 0.05H L 1.0H, 0.1 s L/R 1.0 s March 30, 2006 LCLS Intermediate Power Supplies 4 Paul Bellomo [email protected] POWER SUPPLY Monitor Transductor Gate Drivers To Magnet Load Feedback Transductor Control Power Ground Current Monitor Seller's Control Loop Error Amp I Programming Voltage Klixon opens if magnet overheats Ethernet Controller Current Setpoint From Host Computer Error Amp Feedback Current Monitor Redundant Current Monitor March 30, 2006 LCLS Intermediate Power Supplies Buffer Amp 5 Paul Bellomo [email protected] Interface Inputs to Power Supply from Controller On/Off Discrete, continuous +5V On, 0V Off Programming Voltage Analog, continuous 0 to +5V , 0 to FSV or 0 to FSI Reset Discrete, momentary +5V 100ms pulse Outputs from Power Supply to Controller On/Off Status Discrete, continuous 0V On. +5V Off PS Ready - sum of internal faults Discrete, continuous 0V ready, +5V not ready Output current Analog, continuous From transductors – not from PS Output voltage Analog, continuous 0 to +10V, 0 to FSV Ground current Analog, continuous 0 to +10V, 0 to 100mA March 30, 2006 LCLS Intermediate Power Supplies 6 Paul Bellomo [email protected] Power Supply - Front View IE Power, Incorporated 12 Falconer Drive, Unit 15 Mississauga, Ontario Canada L5N 3L9 905-813-8900 [email protected] • 2.5 kW to 22.5 kW • 208 V / 480 V input • Series and parallelable • 27cm H*48cm W*61cm D • 8.74” * 19” * 24” March 30, 2006 LCLS Intermediate Power Supplies 7 Paul Bellomo [email protected] Power Supply - Rear View J1 J2 Terminal Cover + DC Output - AC Input Totally covered connectors DC Output Cables March 30, 2006 LCLS Intermediate Power Supplies 8 Paul Bellomo [email protected] Current Transductors March 30, 2006 LCLS Intermediate Power Supplies 9 Paul Bellomo [email protected] DC Current Transductors GMW Associates 955 Industrial Road San Carlos, CA 94070 650-802-8292 [email protected] +/- 150A or +/- 600A Accuracy < 2ppm Linearity < 1ppm 0.3 ppm / C Bandwidth 100kHz March 30, 2006 LCLS Intermediate Power Supplies 10 Paul Bellomo [email protected] Intermediate PS Hazard Analysis Energy Hazard Mitigation Electrical Arc flash at input circuit breaker Shock 480VAC, 650VDC, 200VDC PAB = 1 inch Stored PS and magnet energy < 20kJ FPB = 3.7 inches Category Fire Teaspoon amounts of flammable oil in electrolytic filter capacitors Not required. Other components are non-flammable or fire retardant Gravity 100lb chassis Two workers lift with mechanical assistance. Pressure Radiation None Not applicable Temperature Hot chassis/components (100OC) Warning labels on components March 30, 2006 LCLS Intermediate Power Supplies 11 0 PPE, 00 gloves Bleeder resistors, ground hooks across filter capacitors, 00 gloves, safety glasses Totally enclosed chassis Totally covered PS/magnet terminals Listed components when possible EEIP Inspection at SLAC JHAM and STA qualified workers Paul Bellomo [email protected] Hazard Analysis See text for calculations Substation K10B 1500kVA, Z = 5.67% 12.47kV:480V 140ft 5-1/C#600kcmil per phase Operate this CB depend upon the MCC CB for protection Ibf = 11kA Iarc = 7kA 85% Iarc = 6kA Tc = 0.008 sec FPB = 6 inches AFH = 0.2 cal/cm2 Sector 20 MCC 125A C-H HFD3125 100ft 1/C#1AWG per phase LKG-01 100A C-H FD3100 30A Power Supply 30A Power Supply March 30, 2006 LCLS Intermediate Power Supplies LKG-06 Operate this CB or PS CB – Depend upon the rack main CB for protection Ibf = 11kA Iarc = 7kA 85% Iarc = 6kA Tc = 0.007 sec FPB = 5 inches AFH = 0.2 cal/cm2 12 30A Power Supply 30A Power Supply FPB = 4 inches Stored power supply + magnet energy < 20kJ Paul Bellomo [email protected] Status Summary Systems Controls established - EI diagrams made to 85% level Power Supplies All here by April 15 Inspection and bench testing April 15 through April 30 Transductors All here and bench tested Remaining tasks Identify cables from the Ethernet switches and terminal servers to the power supply controllers March 30, 2006 LCLS Intermediate Power Supplies 13 Paul Bellomo [email protected] MCOR Powered Systems with Special thanks to Fernando Rafael March 30, 2006 LCLS MCOR Power Supplies 14 Paul Bellomo [email protected] Uses and Requirements Uses Power 6A, 12A, and 30A correctors, small quadrupoles, and trim magnets that require unipolar or bipolar current Output V, I and P At least 10% greater than magnet standardize value Short term stability 30 ppm RMS, 1 second, Long term stability 400 ppm RMS, 10 second at 30C Stability versus temp 13 ppm / O C, 10 to 100% Ambient 40OF (4 OC) to 113 OF (45 OC) Bandwidth as I source XC04, YC04, XC07, YC07 DC to – 3dB 10Hz Load 0.05H L 1.0H, 0.1 s L/R 1.0 s March 30, 2006 LCLS MCOR Power Supplies 15 Paul Bellomo [email protected] The MCOR System LKG-03 LKG-04 LKG-05 AC Distribution 1 – 100A Main CB 2 – 30A Circuit Breakers AC Distribution 1 – 100A Main CB 2 – 30A Circuit Breakers AC Distribution 1 – 100A Main CB 2 – 30A Circuit Breakers Contingency Space Contingency Space VME Crate VME Crate Up to 16 MCOR PS Up to 16 MCOR PS Blower Blower Blower Up to 16 MCOR PS Up to 16 MCOR PS Up to 16 MCOR PS Blower Blower Blower Bulk Power Supply 60V, 165A Out 480V, 13A @ Prated Bulk Power Supply 60V, 165A Out 480V, 13A @ Prated Bulk Power Supply 60V, 165A Out 480V, 13A @ Prated Contingency Space MCOR Bulk PS Soft-Start Ground Current Monitor Up to 16 MCOR PS Blower Up to 16 MCOR PS Forklift provision March 30, 2006 LCLS MCOR Power Supplies 16 Paul Bellomo [email protected] The MCOR12 March 30, 2006 LCLS MCOR Power Supplies 17 Paul Bellomo [email protected] The MCOR30 March 30, 2006 LCLS MCOR Power Supplies 18 Paul Bellomo [email protected] MCOR Bulk PS Rating Determination Average 13V, 11A per MCOR12 or MCOR30 from magnet list For a rack of three crates of 10 MCOR12s and 3 MCOR30s crates MCOR 13V * 11A 3* * 13 * * 5.6kW rack crate MCOR The total current required in a rack of 3 crates crates MCOR 11A 3* * 13 * * 429A rack crate MCOR The current that must be delivered from the bulk power supply is 5.6kW 50V * Ibulk 0.95 5.6kW 118A 0.95 * 50V Use a 60V, 165A 10kW bulk supply to power three crates of MCORs March 30, 2006 LCLS MCOR Power Supplies 19 Paul Bellomo [email protected] MCOR12 Module Interface Inputs from Controller to Each Module Inhibit (1 for all 16 modules) Discrete, TTL, continuous 0V = On, +5V = Inhibit Programming Voltage Analog, continuous -10V to +10V, -FSI to +FSI Reset (1 for all 16 modules) Discrete, TTL, momentary Reset on +5V rising edge, 0V otherwise Outputs from Each Module to Controller Output current (feedback) Analog, continuous -10V to +10V, -FSI to +FSI Output current (monitor) Analog, continuous -10V to +10V, -FSI to +FSI Module Fault Discrete, continuous 0V = no fault, +5V = fault March 30, 2006 LCLS MCOR Power Supplies 20 Paul Bellomo [email protected] MCOR30 Module Interface Inputs from Controller to Each Module Inhibit (1 for all 16 modules) Discrete, TTL, continuous 0V = On, +5V = Inhibit Programming Voltage Analog, continuous -10V to +10V, -FSI to +FSI Reset (1 for all 16 modules) Discrete, TTL, momentary Reset on +5V rising edge, 0V otherwise Outputs from Each Module to Controller Output current (feedback) Analog, continuous -10V to +10V, -FSI to +FSI Output current (monitor) Analog, continuous -10V to +10V, -FSI to +FSI Output voltage (+ line) Analog, continuous -10V to +10V, -FSV to +FSV Output voltage (- line) Analog, continuous -10V to +10V, -FSV to +FSV Module Fault Discrete, continuous 0V = no fault, +5V = fault March 30, 2006 LCLS MCOR Power Supplies 21 Paul Bellomo [email protected] MCOR Hazard Analysis Energy Hazard Mitigation Electrical Arc flash at input circuit breaker Shock 480VAC, 650VDC, 60VDC in bulk PS and modules PAB = 1 inch Stored and magnet energy < 1kJ FPB = 1 inch Category Fire Trace amounts of flammable oil in electrolytic filter capacitors in bulk PS Not required. Other components are non-flammable or fire retardant Gravity 100lb chassis Two workers lift with mechanical assistance. Pressure Radiation None Not applicable Temperature Hot chassis/components (100OC) Warning labels on components March 30, 2006 LCLS MCOR Power Supplies 22 0 PPE, 00 gloves Bleeder resistors across filter capacitors, 00 gloves, safety glasses Totally enclosed chassis Totally covered PS/magnet terminals Listed components when possible EEIP Inspection at SLAC JHAM and STA qualified workers Paul Bellomo [email protected] Status Power Supplies – MCORs 75 of 75 MCOR12s received and bench tested 20 of 20 MCOR30s received and bench tested 9 crates not yet received – due in April 9 crate blowers are here Most connectors are here 3 bulk power supplies received and bench tested Remaining Tasks Identify MCOR to VME crate cable types, configurations and connectors March 30, 2006 LCLS MCOR Power Supplies 23 Paul Bellomo [email protected] MCOR Ground Current Monitor March 30, 2006 LCLS Ground Current Monitor 24 Paul Bellomo [email protected] MCOR Ground Current Monitor Purpose MCOR system does not include ground current monitoring Indicate when power supply current is straying outside magnet Ramifications Monitored MCOR current is not the magnet current Loss of magnet current causes beam problems Ground current fluctuates causing erratic magnet current Requirements Turn off bulk on excessive ground current Display ground current on local display Separate Injector/Sector 21 and BC1 systems Reference Drawings EI-380-201-31, Schematic Diagram and Chassis Layout March 30, 2006 LCLS Ground Current Monitor 25 Paul Bellomo [email protected] Ground Current Monitor Concept On/Off from IDIM/IDOM IDEC Smart Relay Adjustable Comparator Bulk PS On/Off PS Dataforth DSCA Signal Conditioner/ Isolator March 30, 2006 LCLS Ground Current Monitor 100 ohm resistor 26 Paul Bellomo [email protected] Signal Conditioner and mPLC Dataforth DSCA31-06 March 30, 2006 LCLS Ground Current Monitor IDEC Smart Relay 27 Paul Bellomo [email protected] Ethernet communication Ethernet Module 120VAC Power Supply for Signal Conditioners and MicroPLC 24VDC Bulk 1 On/Off to IDIM Bulk 2 On/Off to IDIM Bulk 3 On/Off to IDIM IDOM On/Off Bulk 1 On/Off/ Fault IDOM On/Off Bulk 2 IDOM On/Off Bulk 3 100 W MicroPLC and Digital/Analog Expansion Modules On/Off/ Fault Local Test -10V to +10V -10V to +10V 48 magnets MCORs Local Test 24V Local Reset 24V IDOM 1/2 Reset 24V IDOM 3 Reset -10V to +10V Soft Start Bulk PS 1 Signal Conditioner 0 – 10V Signal Conditioner 0 – 10V Signal Conditioner 0 – 10V March 30, 2006 LCLS Ground Current Monitor Soft Start Bulk PS 2 32 magnets MCORs Local Test 100 W On/Off/ Fault Soft Start Bulk PS 3 MCORs 32 magnets Local Test 100 W 28 Paul Bellomo [email protected] Ground Current Monitor Interface Requirements Inputs to Ground Current Monitor from Computer On/Off Command - Bulk PS 1, 2 or 3 3 Discrete, momentary +24V=On, 0V=Off Remote Reset - Bulk PS 1 & 2 1 Discrete, momentary +24V=Reset Remote Reset - Bulk PS 3 1 Discrete, momentary +24V=Reset Inputs to Ground Current Monitor from Other Places Ground I from Bulk PS 1, 2 or 3 resistors 3 Analog, continuous 0 to +10V = 0 to 100mA Local chassis Reset button, Bulk PS 1, 2, 3 1 Discrete, momentary +24V=Reset Local chassis Test button, Bulk PS 1,2,3 1 Discrete, momentary +24V=initiates fault Outputs from Ground Current Monitor to Computer On/Off Status - Bulk PS 1, 2 or 3 3 Discrete, continuous +24V=On, 0V=Off On/Off/Fault Status - Bulk PS 1, 2 or 3 Serial digital data (future) Via Ethernet module Ground Current - Bulk PS 1, 2 or 3 Serial digital data (future) Via Ethernet module Outputs from Ground Current Monitor to Others On/Off Command to Bulk PS soft start 1, 2 or 3 March 30, 2006 LCLS Ground Current Monitor 3 Discrete, continuous 29 Contact, closed=On, open = Off Paul Bellomo [email protected] Ground Current Monitor Status and Remaining Tasks Schematic diagrams completed, but needs redrawing Job Shopper Designer on board Chassis drawing completed but needs redrawing Job Shopper Designer on board Software for microPLC written, but needs revision Parts ordered and received (except for chassis) Fabrication not yet started Identify all interconnecting cables and connectors March 30, 2006 LCLS Ground Current Monitor 30 Paul Bellomo [email protected] MCOR Bulk Power Supply Soft-Start (Courtesy of Fernando Rafael) March 30, 2006 LCLS Bulk PS Soft-Start 31 Paul Bellomo [email protected] MCOR Soft-Start Problem SPEAR 3 experienced MCOR30 bridge MOSFET failures during bulk power supply turn on It was determined that, with a fixed front panel controlled set-point, the bulk power supply output voltage was rising too quickly. The MCOR crate auxiliary power supply oscillated Solution and Requirements Soft-start circuit to slowly apply the bulk power supply set-point (and hence ramp the output voltage) after bulk power supply turn on. March 30, 2006 LCLS Bulk PS Soft-Start 32 Paul Bellomo [email protected] MCOR Soft-Start On/Off from Ground Current Monitor PS On/Off ckt +V Front Panel V setpoint Soft-start V setpoint to PS March 30, 2006 LCLS Bulk PS Soft-Start RTN 33 Paul Bellomo [email protected] MCOR Soft-Start Status and Remaining Tasks Drawings Schematic diagram and chassis drawings completed PCB layout is needed Cables and connectors need specification Parts Electronic and chassis parts are here Need to purchase PCB Fabrication Chassis and PCBs are not yet started Testing Not started March 30, 2006 LCLS Bulk PS Soft-Start 34 Paul Bellomo [email protected] Ground Current Monitor and Soft-Start Energy Hazard Mitigation Electrical Shock Fire None Not Gravity None Not applicable Pressure Radiation Temperature None Not applicable March 30, 2006 LCLS Bulk PS Soft-Start 120VAC in chassis 35 Listed components when possible EEIP Inspection at SLAC JHAM and STA qualified workers applicable Paul Bellomo [email protected] Power Supply Racks March 30, 2006 LCLS Racks 36 Paul Bellomo [email protected] 120V, 1 F, 20A 480V, 3 F, 125A 120V, 1 F, 20A 120V, 1 F, 20A 480V, 3 F, 125A 120V, 1 F, 20A 120V, 1 F, 20A 480V, 3 F, 125A 120V, 1 F, 20A 480V, 3 F, 125A 120V, 1 F, 20A 480V, 3 F, 125A 120V, 1 F, 20A 480V, 3 F, 125A LKG-01 LKG-02 LKG-03 LKG-04 LKG-05 LKG-06 AC Distribution 1 – 100A Main CB 4 – 30A Circuit Breakers AC Distribution 1 - 100A Main CB 4 – 30A Circuit Breakers AC Distribution 1 – 100A Main CB 2 – 30A Circuit Breakers AC Distribution 1 – 100A Main CB 2 – 30A Circuit Breakers AC Distribution 1 – 100A Main CB 2 – 30A Circuit Breakers AC Distribution 1 – 100A Main CB 4 – 30A Circuit Breakers Transductors Transductors Contingency Space Contingency Space VME Crate VME Crate Up to 16 MCOR PS Up to 16 MCOR PS Blower Blower Blower Up to 16 MCOR PS Up to 16 MCOR PS Up to 16 MCOR PS Contingency Space PS Controller PS Controller PS Controller PS Controller PS Controller Transductors MCOR Bulk PS Soft-Start Ground Current Monitor PS Controller Up to 16 MCOR PS Blower Up to 16 MCOR PS BX01, BX02 25V, 375A Out 480V, 13A @ Prated BXS 33V, 300A Out 480V, 13A @ Prated BXH1...BXH4 25V, 375A Out 480V, 13A @ Prated SOL1 33V, 300A Out 480V, 13A @ Prated BXH1...BXH4 25V, 375A Out 480V, 13A @ Prated SOL2 200V, 50A Out 480V, 13A @ Prated Forklift provision March 30, 2006 LCLS Racks Blower Blower Blower Bulk Power Supply 60V, 165A Out 480V, 13A @ Prated Bulk Power Supply 60V, 165A Out 480V, 13A @ Prated Bulk Power Supply 60V, 165A Out 480V, 13A @ Prated Forklift provision 37 BX11...BX14 25V, 375A Out 480V, 13A @ Prated BX11...BX14 25V, 375A Out 480V, 13A @ Prated Forklift provision Paul Bellomo [email protected] Rack Requirements References Specification ESD 1.2-154, R0 Seismic Document Drawings (later from Optima) Electrical Requirements Keep personnel from inadvertent contact – shock and arc flash Accept AC power and controls interfaces Maintain ground continuity Be reasonably EMI – proof Mechanical Requirements Carry weight of installed components – 1000 lbs per bay Seismic capable Neatly contain equipment Ventilated so that equipment does not overheat March 30, 2006 LCLS Racks 38 Paul Bellomo [email protected] Seismic Requirements Reference: I-720-0A24E-002, Specification for Seismic Design of Buildings, Structures, Equipment and Systems at SLAC, December 4, 2000 Item 6, Page 9 – Rack is defined as Programmatic Equipment H & V Floor Response Spectra Page 6, Fig 3 and Page 7, Fig 4 for Mechanical Systems Table 12 – Performance Level 6.5 to 8.5 – Adequate restraint and anchorage. Only minor damage incurred Optima is required to submit rack structural drawings and seismic analysis prior to release for fabrication March 30, 2006 LCLS Racks 39 Paul Bellomo [email protected] Rack Hazard Analysis Energy Hazard Mitigation Electrical Shock 480V Arc Flash 0.2cal/cm^2 FPB=5 inches Class Fire None All non-flammable materials Gravity Review Pressure Radiation Temperature None March 30, 2006 LCLS Racks 0 PPE, Class 00 gloves Proper grounding All welded construction Metal straps between doors and frame EEIP inspection at SLAC 3,000lbs of rack design and fabrication drawings by seismic committee Secure in accordance with seismic committee guidance Not applicable 40 Paul Bellomo [email protected] See text for calculations Substation K10B 1500kVA, Z = 5.67% 12.47kV:480V 140ft 5-1/C#600kcmil per phase Operate this CB depend upon the MCC CB for protection Ibf = 11kA Iarc = 7kA 85% Iarc = 6kA Tc = 0.008 sec FPB = 6 inches AFH = 0.2 cal/cm2 Sector 20 MCC 125A C-H HFD3125 100ft 1/C#1AWG per phase LKG-01 100A C-H FD3100 30A Power Supply March 30, 2006 LCLS Racks 30A Power Supply LKG-06 Operate this CB or PS CB – Depend upon the rack main CB for protection Ibf = 11kA Iarc = 7kA 85% Iarc = 6kA Tc = 0.007 sec FPB = 5 inches AFH = 0.2 cal/cm2 41 30A Power Supply 30A Power Supply FPB = 4 inches Stored power supply + magnet energy < 20kJ Paul Bellomo [email protected] Racks Status and Remaining Tasks Purchase order placed with Optima in February Rack design is acceptable - First Article released for fabrication Awaiting Optima seismic analysis Awaiting “First Article” delivery Delivery goal May 30, 2006 Assemble all systems into racks Test systems in racks prior to field installation March 30, 2006 LCLS Racks 42 Paul Bellomo [email protected] DC Power Cables March 30, 2006 LCLS Cables 43 Paul Bellomo [email protected] DC Cable and Conductor Sizing Per 2005 NEC Power Supply Required I= PS I /Derating Conductor Size 25V, 375A 375A/(0.65*0.87) = 663A 1/C500kcmil 700A 33V, 300A 300A/(0.65*0.87) = 531A 350kcmil 570A, use 1/C500kcmil 60V, 165A 165A/(0.65*0.87) = 292A 1/C2/0AWG 300A 200V, 50A 50A/0.87 = 57A 3/C#6AWG 75A 60V, 30A 30A/0.87 = 34A 3/C#10AWG 40A 40V, 12A 12A/0.87 =13A 3/C#12AWG 30A Basis – copper conductors, 90C insulation, max 45C ambient, 2005 NEC Tables 310-16 and 310-17 and cable tray fill per Article 392 for multi-conductor and single conductor cable, respectively. Flexible stranding, low smoke, zero halogen, suitable for cable tray use March 30, 2006 LCLS Cables 44 Paul Bellomo [email protected] DC Cable Hazard Analysis Energy Hazard Mitigation Electrical Shock Proper Fire Overheating Smoke Size Gravity Weight of many cables Support systems meet seismic, NEC and NEMA VE-1 requirements Pressure None Not applicable Radiation None Not applicable Temperature Hot Size March 30, 2006 LCLS Cables insulation voltage class Jackets on cables pulled in cable trays Isolate cables from public via raceways conductors for ampacity per NEC Use fire retardant insulations and jackets Low smoke, zero halogen construction cables from excessive current and/or packing 45 conductors for ampacity per NEC to keep temperatures within insulation rating Cable tray and raceway fill and isolation per NEC Paul Bellomo [email protected] This is the Last Slide Test, Installation and Commissioning Plan Receive and bench test equipment – procedures exist Install in purchased racks in Building 24 Test as complete systems in B24 – need updated procedure Forklift entire rack assemblies from B24 to Sector 20 Install in Sector 20 Field test power systems – need updated procedure March 30, 2006 LCLS Power Supplies 46 Paul Bellomo [email protected]