LCLS Injector, Sector 21 and BC1 New Power Supplies Needed for First Injection P. Bellomo

Paul Bellomo

LCLS Power Supplies [email protected]

March 30, 20061

LCLS Injector, Sector 21 and BC1

New Power Supplies

Needed for First Injection

P. Bellomo

http://www-ssrl.slac.stanford.edu/

Paul Bellomo


March 30, 20062

List of Needed Magnet Power SuppliesRefer to the list in the binder

Intermediate Power Supplies6 dipole and quadrupole magnets require 8 power supplies

13 on order, 1 contingency of each type

MCOR12 Power Modules72 corrector, quadrupole and trim magnets require 72 power supplies

75 on order, 3 are contingency

MCOR30 Power Modules12 corrector, quadrupole and trim magnets require 12 power supplies

20 on order, 8 contingency

MCOR Bulk Power Supplies3 needed, 3 ordered, 0 contingency


Paul BellomoLCLS Intermediate Power Supplies [email protected]

March 30, 20063

Intermediate Power Supplies



March 30, 20064

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

Performance Requirements



March 30, 20065



March 30, 20066

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

Interface



March 30, 20067

IE Power, Incorporated12 Falconer Drive, Unit 15Mississauga, OntarioCanada L5N [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”

Power Supply - Front View



March 30, 20068

Power Supply - Rear View

J1 J2

+ -DC Output AC Input

DC Output Cables

TerminalCover

Totally covered connectors



March 30, 20069

Current Transductors



March 30, 200610

GMW Associates955 Industrial RoadSan Carlos, CA 94070650-802-8292 [email protected]

+/- 150A or +/- 600A Accuracy < 2ppm Linearity < 1ppm 0.3 ppm / C Bandwidth 100kHz

DC Current Transductors

mailto:[email protected]



March 30, 200611

Intermediate PS Hazard AnalysisEnergy 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 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

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.

PressureRadiation

None Not applicable

Temperature Hot chassis/components (100OC) Warning labels on components



March 30, 200612

Hazard Analysis

Operate this CB or PS CB – Depend upon the rack main CB for protectionIbf = 11kAIarc = 7kA85% Iarc = 6kATc = 0.007 secFPB = 5 inchesAFH = 0.2 cal/cm2

100AC-H

FD3100

30A

LKG-01

Power Supply

Power Supply

30A 30A

LKG-06

Power Supply

Power Supply

30A

125A C-H HFD3125

100ft 1/C#1AWG per phase

Substation K10B1500kVA, Z = 5.67%

12.47kV:480V140ft 5-1/C#600kcmil per phase

FPB = 4 inches Stored power

supply + magnet energy < 20kJ

See text for calculations

Operate this CB - depend upon the MCC CB for protectionIbf = 11kAIarc = 7kA85% Iarc = 6kATc = 0.008 secFPB = 6 inchesAFH = 0.2 cal/cm2

Sector 20 MCC



March 30, 200613

Status SummarySystems

Controls established - EI diagrams made to 85% level

Power SuppliesAll here by April 15

Inspection and bench testing April 15 through April 30

TransductorsAll here and bench tested

Remaining tasksIdentify cables from the Ethernet switches and terminal servers to the power supply controllers


Paul BellomoLCLS MCOR Power Supplies [email protected]

March 30, 200614

MCOR Powered Systems

with

Special thanks to Fernando Rafael



March 30, 200615

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 sourceXC04, YC04, XC07, YC07

DC to – 3dB 10Hz

Load 0.05H L 1.0H, 0.1 s L/R 1.0 s



March 30, 200616

The MCOR System



March 30, 200617

The MCOR12



March 30, 200618

The MCOR30



March 30, 200619

Average 13V, 11A per MCOR12 30 from magnet list

For a rack of three crates of 10 MCOR12s and 3 MCOR30scrates 13 113* 13 5 6rack

The total current required in a rack of 3 cratescrat3*

or MCOR

MCOR V * A* * * . kWcrate MCOR

es 1113 429rack

The current that must be delivered from the bulk power supply is 5 6 5 650 1180 95 0 95 50

Use a 60V, 165A 10kW bulk supply to power three crates of MCORs

MCOR A* * * Acrate MCOR

. kW . kWV * I Abulk. . * V

MCOR Bulk PS Rating Determination



March 30, 200620

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

MCOR12 Module Interface



March 30, 200621

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

MCOR30 Module Interface



March 30, 200622

MCOR Hazard AnalysisEnergy 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 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

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.

PressureRadiation

None Not applicable

Temperature Hot chassis/components (100OC) Warning labels on components



March 30, 200623

Status

Power Supplies – MCORs75 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 TasksIdentify MCOR to VME crate cable types, configurations and connectors


Paul BellomoLCLS Ground Current Monitor [email protected]

March 30, 200624

MCOR Ground Current Monitor



March 30, 200625

MCOR Ground Current MonitorPurpose

MCOR system does not include ground current monitoringIndicate when power supply current is straying outside magnet

RamificationsMonitored MCOR current is not the magnet currentLoss of magnet current causes beam problemsGround current fluctuates causing erratic magnet current

RequirementsTurn off bulk on excessive ground currentDisplay ground current on local displaySeparate Injector/Sector 21 and BC1 systems

Reference DrawingsEI-380-201-31, Schematic Diagram and Chassis Layout



March 30, 200626

Ground Current Monitor Concept



March 30, 200627

Signal Conditioner and PLC

Dataforth DSCA31-06 IDEC Smart Relay



March 30, 200628



March 30, 200629

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 3 Discrete, continuous Contact, closed=On, open =

Off

Ground Current Monitor Interface Requirements



March 30, 200630

Ground Current Monitor

Status and Remaining Tasks

Schematic diagrams completed, but needs redrawingJob Shopper Designer on board

Chassis drawing completed but needs redrawingJob 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


Paul BellomoLCLS Bulk PS Soft-Start [email protected]

March 30, 200631

MCOR Bulk Power Supply Soft-Start(Courtesy of Fernando Rafael)



March 30, 200632

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, 200633

MCOR Soft-Start

PS On/Off ckt

On/Off from Ground Current Monitor

RTN

+V

Front Panel V setpointSoft-start V

setpoint to PS



March 30, 200634

MCOR Soft-Start Status and Remaining Tasks

DrawingsSchematic diagram and chassis drawings completedPCB layout is neededCables and connectors need specification

PartsElectronic and chassis parts are hereNeed to purchase PCB

FabricationChassis and PCBs are not yet started

TestingNot started



March 30, 200635

Ground Current Monitor and Soft-StartEnergy Hazard Mitigation

Electrical Shock 120VAC in chassis Listed components when possible EEIP Inspection at SLAC JHAM and STA qualified workers

Fire None Not applicable

Gravity None Not applicable

PressureRadiationTemperature

None Not applicable


Paul BellomoLCLS Racks [email protected]

March 30, 200636

Power Supply Racks



March 30, 200637

BXH1...BXH425V, 375A Out

480V, 13A @ Prated

BXH1...BXH425V, 375A Out

480V, 13A @ Prated

SOL133V, 300A Out

480V, 13A @ Prated

SOL2200V, 50A Out

480V, 13A @ Prated

Transductors

Forklift provision

AC Distribution1 – 100A Main CB

4 – 30A Circuit Breakers

Up to 16 MCOR PS

Up to 16 MCOR PS

480V

, 3 F

, 12

5A

120V

, 1 F

, 20

A

BX01, BX0225V, 375A Out

480V, 13A @ Prated

Up to 16 MCOR PS

BXS33V, 300A Out

480V, 13A @ Prated

Transductors

Forklift provision

Bulk Power Supply60V, 165A Out

480V, 13A @ Prated

Up to 16 MCOR PS


480V, 13A @ Prated

VME CratePS ControllerPS Controller

PS ControllerPS Controller

Forklift provision

Blower

Blower

Blower

Blower

PS Controller

Blower

Up to 16 MCOR PS


480V, 13A @ Prated

Blower

Up to 16 MCOR PS

BX11...BX1425V, 375A Out

480V, 13A @ Prated

BX11...BX1425V, 375A Out

480V, 13A @ Prated

PS Controller

Transductors

Up to 16 MCOR PS

LKG-01 LKG-02 LKG-03 LKG-04 LKG-05 LKG-06

ContingencySpace

VME Crate

ContingencySpace

120V

, 1 F

, 20

A

480V

, 3 F

, 12

5A

480V

, 3 F

, 12

5A

120V

, 1 F

, 20

A

120V

, 1 F

, 20

A

480V

, 3 F

, 12

5A

120V

, 1 F

, 20

A

480V

, 3 F

, 12

5A

120V

, 1 F

, 20

A

120V

, 1 F

, 20

A

480V

, 3 F

, 12

5A

120V

, 1 F

, 20

A

AC Distribution1 - 100A Main CB






Blower

ContingencySpace





Ground Current MonitorMCOR Bulk PS Soft-Start



March 30, 200638

Rack RequirementsReferences

Specification ESD 1.2-154, R0Seismic DocumentDrawings (later from Optima)

Electrical RequirementsKeep personnel from inadvertent contact – shock and arc flashAccept AC power and controls interfacesMaintain ground continuityBe reasonably EMI – proof

Mechanical RequirementsCarry weight of installed components – 1000 lbs per baySeismic capableNeatly contain equipmentVentilated so that equipment does not overheat



March 30, 200639

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, 200640

Rack Hazard AnalysisEnergy Hazard Mitigation

Electrical Shock 480V Arc Flash 0.2cal/cm^2 FPB=5 inches

Class 0 PPE, Class 00 gloves Proper grounding All welded construction Metal straps between doors and frame EEIP inspection at SLAC

Fire None All non-flammable materials

Gravity 3,000lbs Review of rack design and fabrication drawings by seismic committee

Secure in accordance with seismic committee guidance

PressureRadiationTemperature

None Not applicable



March 30, 200641

Operate this CB or PS CB – Depend upon the rack main CB for protectionIbf = 11kAIarc = 7kA85% Iarc = 6kATc = 0.007 secFPB = 5 inchesAFH = 0.2 cal/cm2

100AC-H

FD3100

30A

LKG-01

Power Supply

Power Supply

30A 30A

LKG-06

Power Supply

Power Supply

30A

125A C-H HFD3125

100ft 1/C#1AWG per phase

Substation K10B1500kVA, Z = 5.67%

12.47kV:480V140ft 5-1/C#600kcmil per phase

FPB = 4 inches Stored power

supply + magnet energy < 20kJ

See text for calculations

Operate this CB - depend upon the MCC CB for protectionIbf = 11kAIarc = 7kA85% Iarc = 6kATc = 0.008 secFPB = 6 inchesAFH = 0.2 cal/cm2

Sector 20 MCC



March 30, 200642

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


Paul BellomoLCLS Cables [email protected]

March 30, 200643

DC Power Cables



March 30, 200644

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, 200645

DC Cable Hazard AnalysisEnergy Hazard Mitigation

Electrical Shock Proper insulation voltage class Jackets on cables pulled in cable trays Isolate cables from public via raceways

Fire Overheating Smoke

Size conductors for ampacity per NEC Use fire retardant insulations and

jackets Low smoke, zero halogen construction

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 cables from excessive current and/or packing

Size conductors for ampacity per NEC to keep temperatures within insulation rating

Cable tray and raceway fill and isolation per NEC


Paul Bellomo


March 30, 200646

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


Documents

LCLS Injector, Sector 21 and BC1 New Power Supplies Needed for First Injection P. Bellomo