January 12, 2006 ATF2 DC Magnet Power Supplies 1

ATF2 DC Magnet Power Supplies

Paul Bellomo and Briant Lam

January 12, 2006 ATF2 DC Magnet Power Supplies 2

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

Scope and Summary

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Term Definition

Availability MTBF / (MTBF+Time to repair)

MTBF Mean time between failures in hours

R(t) Reliability or probability of success with time

Failure rate in hr -1. These are the reciprocals of the MTBFs

N Number of bulk power supplies

m Minimum number of power modules needed for operation

n Number of power modules in a system

m=1/n=2 One out of two redundant power module configuration

m=2/n=3 Two out of three redundant power module configuration

m=3/n=4 Three out of four redundant power module configuration

m=4/n=5 Four out of five redundant power module configuration

Droop Output voltage decrease with increasing load

Glossary of Terms

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Phase 1 – Preliminary Power Supply List (For Phase 2)

Type Quantity Quantity Volts Amps kW

Quadrupole 8 8 20 150 3.0

Dipole 4 1 20 400 8.0

Quadrupole 6 6 20 150 3.0

Dipole 3 3 20 200 4.0Quadrupole 16 16 20 50 1.0Sextupole 5 5 20 50 1.0Octupole 2 2 20 50 1.0

44 41

Final Focus

Total Magnet and Power Supply Quantities

Magnet Power Supply Ratings

Chicane

Matching

Extraction Quadrupoles

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• 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

Phase 1 – Design Basis

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Phase 1 - Typical System Block Diagram

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t N t1 N

t N t1 N

n!1 ( n k )

Single and multiple bulk power supply reliability

R ( t ) e and R e

R e R e

Less rectifiers greater reliability greater Availability

Module redundancy

Start with Binomial Expansion

R ( t ) (

n 1

t k t n k!k !

k m 1

t1

nt k t n kn!

m/n ( n k )!k !k m

-m t n t tm/n 1

)( e ) (1 e )

R ( t ) e

R ( t ) ( )( e ) (1 e )

R (t)=ne me R ( t ) e

Greater reliability implies greater Availability

Phase 1 – Availability Improvement by Parts Reduction and Module Redundancy

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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

Phase 1 - Bulk Power Supply Types

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

Purpose – voltage source that provides raw power for modules

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Elgar Electronics Corporation9250 Brown Deer RoadSan Diego, CA 92121Website: www.elgar.com

IE Power12 Falconer Drive, Unit 15Mississauga, OntarioCanada L5N 3L9www.iepower.com

Lambda-EMIAroma Square Bldg 5FKamata, Ohta - KuTokyo 144-8721 Japanwww.densei-lambda.com

Matsusada - Shiga Headquarters745 Aoji-Cho,Kusatsu -City, Shiga, 525-0041 Japan www.matsusada.com

Phase 1 - Bulk Power Supply Manufacturers

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Phase 1 – Power Module Buck Regulator Topology

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• 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

Phase 1 – Power Module Current Sharing Options

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Phase 1 – Democratic Current Share Circuitry

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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

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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.

January 12, 2006 ATF2 DC Magnet Power Supplies 15

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, JapanTel. +81 3 3225 8910

Phase 1 - Current Transductor

0.3 ppm / OC

Purpose

Monitors output current for use in regulation loop

Monitors current for system display and histograms

January 12, 2006 ATF2 DC Magnet Power Supplies 16

Phase 1 - Cost Estimate

MaterialsThree power modules, add current share $2,500Bulk power supply $4,000Power supply controller $2,000Miscellaneous hardware $1,000Materials total $9,500

Labor1 Engineer for 5 months @ 15% time@ $19k/month $14,0001 Technician for 5 months @ 10% time @ $11k/month $5,500Labor total $19,500

Total cost $29,000

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Phase 1 - Schedule and Status

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Phase 2 - Configuration of 41 Systems

Assumes racks are available and suitable for use as depicted – Brown modules, Blue spares

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Phase 2 - Cost Estimate

Item Name Quantity Cost (k$ each) Item Total k$ Cost

Bulk power supplies 9 10.0 90.0

Power supply crates 30 1.5 45.0

Power modules 117 1.0 117.0

Dipole power supply 1 10.0 10.0

Controllers 41 2.5 102.5

Transductors 41 0.7 28.7

Intrarack cables 41 0.9 36.9

Shipping 1 10.0 10.0

Material total 440.1

FY2006 300.0

FY2007 140.1

Skill Months Rate (k$/Mo) % Time Labor Cost

Engineer 19 19 35% 126.4

Coordinator/Technician 19 11 50% 104.5

Labor Total 230.9

FY2006 142.8

FY2007 83.3

Total Phase 2 671.0

Material Costs (M&S)

Labor Costs (ED&I)

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Phase 2 - Schedule

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Phase 3 – Recommended Spare Parts

ItemSystem

Quantity

Recommended

Spares Quantity

Spares Cost

k$

Bulk/Dipole power supplies

10 1 10.0

Power supply crates 30 2 3.0

Power supply modules 117 13 13.0

Ethernet controllers 41 4 10.0

Transductors 41 2 1.4

Intra-rack cables 41 1 0.9

Total spares cost 38.3

January 12, 2006 ATF2 DC Magnet Power Supplies 22

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

Phase 3 – Installation and Training

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Phase 3 - Schedule

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Phase 3 - Costs

Item Name Quantity Cost (k$ each) Item Total k$ Cost

AC and DC long haul cables (KEK supplied) 6 0.0 0.0

AC conduits DC cable trays (KEK supplied) 41 0.0 0.0

Controls, cables, tray/conduit (KEK supplied) 41 0.0 0.0

Racks, AC Dist, Test equipment (KEK supplied) 1 0.0 0.0

Travel (Round Trip) 5 1.5 7.5

90 days Per Diem ($150 lodging + $100 MIE) 5 22.5 112.5

Material FY2007 120.0

Skill Months Rate each (k$/Mo) Labor Cost

SLAC Engineer (training, commissioning) 3 19 57.0

2 SLAC Technicians (mount parts, wire, test) 3 11 66.0

2 SLAC Technicians (pull and terminate cables) 3 11 66.0

Labor FY2007 189.0

Total Phase 3 309.0

Material Costs (M&S)

Labor Costs (ED&I - All Personnel 100% Time)

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Cost Summary and Closing Slide

Phase 1 - Demonstration $29k

Phase 2 – Design $671k

Phase 3 - Spare parts $38.3

Phase 3 – Installation, Training and Commissioning $309k

Total $1047.3k

Material

Labor

$607.9k 58%

$439.4 42%

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Discussion Issues and Closing Slide

SLAC provides fully assembled racks with internal AC distribution – this will reduce installation and travel costs.

Thank you!