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ATF2 DC Magnet Power Supplies Paul Bellomo and Briant Lam

ATF2 DC Magnet Power Supplies Paul Bellomo and Briant Lam. Scope and Summary. Phase 1 – Demonstration Phase To demonstrate performance, control and redundancy. One (1) system with four modules, each rated 20V, 50A in a three out of four configuration, for a rated output of 20V 150A.

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ATF2 DC Magnet Power Supplies Paul Bellomo and Briant Lam

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  1. ATF2 DC Magnet Power Supplies Paul Bellomo and Briant Lam ATF2 DC Magnet Power Supplies

  2. Scope and Summary • Phase 1 – Demonstration Phase • To demonstrate performance, control and redundancy. One (1) system with four modules, each rated 20V, 50A in a three out of four configuration, for a rated output of 20V 150A. • Major components. Ethernet controller, bulk power supply, power supply modules and crate, current transductor, and interconnecting cables. These components might not be exactly the same as the Phase 2 components. • $29k cost. March 31, 2006 completion • Phase 2 – System Design Phase • Forty-one (41) systems for accelerator use • Major components. Ethernet controllers, bulk power supplies, power supply modules and crate, current transductor, and interconnecting cables • $671k cost. Start April 1, 2006 and October 31, 2007 delivery • Phase 3 – Installation, Training and Commissioning Phase • Spares, installation, training, and maintenance issues. Spares cost $38.3k. Installation Training and Commissioning Cost $309k ATF2 DC Magnet Power Supplies

  3. Glossary of Terms ATF2 DC Magnet Power Supplies

  4. Phase 1 – Preliminary Power Supply List (For Phase 2) ATF2 DC Magnet Power Supplies

  5. Phase 1 – Design Basis • Forty-one (41) DC power supplies • All are 20V output, current outputs are multiples of 50A • A 20V, 50A modular approach will minimize number of power supply types, spare parts inventory and maintenance • A modular approach further suggests redundancy for high availability (HA) • Buck regulator modules are high efficiency, switch-mode. Switching frequency is ≥ than 20 kHz for audible quietness and small size ATF2 DC Magnet Power Supplies

  6. Phase 1 - Typical System Block Diagram ATF2 DC Magnet Power Supplies

  7. Phase 1 – Availability Improvement by Parts Reduction and Module Redundancy ATF2 DC Magnet Power Supplies

  8. Phase 1 - Bulk Power Supply Types Purpose – voltage source that provides raw power for modules • Simple Rectifier Bulk Supply • 6 or 12 pulse • Transformer matches line V to load V. Operates @ 50Hz – LARGE and heavy • Control and interface issue • Difficult to rack-mount • Not recommended • Switch-mode Bulk Power Supply • Line to load V matching transformer is downstream of high frequency > 20kHz switching element. Small size and light • Each 30V, 400A 12kW • Recommended ATF2 DC Magnet Power Supplies

  9. Phase 1 - Bulk Power SupplyManufacturers Elgar Electronics Corporation9250 Brown Deer RoadSan Diego, CA 92121 Website: www.elgar.com IE Power 12 Falconer Drive, Unit 15Mississauga, OntarioCanada L5N 3L9www.iepower.com Lambda-EMIAroma Square Bldg 5F Kamata, Ohta - KuTokyo 144-8721 Japanwww.densei-lambda.com Matsusada - Shiga Headquarters 745 Aoji-Cho,Kusatsu -City, Shiga, 525-0041 Japan www.matsusada.com ATF2 DC Magnet Power Supplies

  10. Phase 1 – Power Module Buck Regulator Topology ATF2 DC Magnet Power Supplies

  11. Phase 1 – Power Module Current Sharing Options • Master-slave. Failure of master takes down entire set of modules. Defeats the redundancy intent. Not recommended • Droop. Do nothing. Connect the power supply outputs in parallel. Relies on degrading output impedance of the power supplies to equalize the power supply or module output currents. Stability acceptable but regulation (immunity to transients) suffers. No control over current sharing precision. Not recommended • Democratic. Recommended approach and discussed further in subsequent slides ATF2 DC Magnet Power Supplies

  12. Phase 1 – Democratic Current Share Circuitry ATF2 DC Magnet Power Supplies

  13. Phase 1 – The Power Modules • Purpose – current regulation of magnet current • All 20V, 50A • Parallel for current share and redundancy • OCEM Italy IE Power Canada ATF2 DC Magnet Power Supplies

  14. Phase 1 - Ethernet Power Supply Controller • Purpose • Interfaces remote computer to power supply • Closed loop control for current setting and regulation • Features • EPICS IOC (if desired by KEK, but not yet integrated into the demonstration controller) • 100Mbps TCP/IP communications via the UDP protocol • Built on excellent performance of controllers employed in PEP and SPEAR, ≥ 300,000hrs MTBF. Controllers slated for LCLS project use. ATF2 DC Magnet Power Supplies

  15. Phase 1 - Current Transductor Purpose Monitors output current for use in regulation loop Monitors current for system display and histograms GMW Associates955 Industrial RoadSan Carlos, CA 94070650-802-8292 ian@gmw.com Hakuto Company Ltd. Scientific Equipment Department, 1-13, 1-chome, Shinjuku, Shinjuku-ku, Tokyo 160, Japan Tel. +81 3 3225 8910 0.3 ppm / OC ATF2 DC Magnet Power Supplies

  16. Phase 1 - Cost Estimate Materials Three power modules, add current share $2,500 Bulk power supply $4,000 Power supply controller $2,000 Miscellaneous hardware $1,000 Materials total $9,500 Labor 1 Engineer for 5 months @ 15% time@ $19k/month $14,000 1 Technician for 5 months @ 10% time @ $11k/month $5,500 Labor total $19,500 Total cost $29,000 ATF2 DC Magnet Power Supplies

  17. Phase 1 - Schedule and Status ATF2 DC Magnet Power Supplies

  18. Phase 2 - Configuration of 41 Systems Assumes racks are available and suitable for use as depicted – Brown modules, Blue spares ATF2 DC Magnet Power Supplies

  19. Phase 2 - Cost Estimate ATF2 DC Magnet Power Supplies

  20. Phase 2 - Schedule ATF2 DC Magnet Power Supplies

  21. Phase 3 – Recommended Spare Parts ATF2 DC Magnet Power Supplies

  22. Phase 3 – Installation and Training • KEK provides site: • AC panel-board locations for power supply input power • DC cable tray layouts • Locations of the remote computer connections and termination points • Details of the magnet and personnel protection systems • Rack details • System software • SLAC provides: • Wiring diagram for each of the 41 systems. These diagrams show the intra-rack cables. • Installation drawings of the AC power conduits and cables. • Installation drawings showing the routing of DC cables from the power supplies to the magnet loads via the KEK Cable tray system • Controller software ATF2 DC Magnet Power Supplies

  23. Phase 3 - Schedule ATF2 DC Magnet Power Supplies

  24. Phase 3 - Costs ATF2 DC Magnet Power Supplies

  25. Cost Summary and Closing Slide ATF2 DC Magnet Power Supplies

  26. Discussion Issues and Closing Slide SLAC provides fully assembled racks with internal AC distribution – this will reduce installation and travel costs. Thank you! ATF2 DC Magnet Power Supplies

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