Magnet Controls GroupOctober 4, 2006 1 Scope, Cost Estimate and Schedule To Complete The LCLS Magnet...

Magnet Controls GroupOctober 4, 20061

Scope, Cost Estimate and Schedule

To Complete The

LCLS Magnet PS Controls

P Bellomo and Kristi Luchini


Topics

Scope

ETC

DescriptionsAreas

Intermediate Power Supplies and Controls

MCOR Power Supplies and Controls

Kicker Pulsers

Schedule

Cost Details


Scope

Magnet power supplies and associated controls

Hardware from dc output terminals on power supply to the EPICS - Ethernet Interface. Local control software

Includes

Power supplies, power supply controllers, VME controls, PLCs current transductors, and intra-rack cables, rack mounting and other miscellaneous equipment. ED&I, M&S and Assembly.

Does not include

Racks, long haul cables, global control software, field installation

Areas – primarily downstream of Tune-up Dump

Complete by March 31, 2008


Scope


Estimate to Complete

WBS Task EDI (k$) MS Labor Comments

1.01.03.05.09 Global 772 0 0 EDI + Management

1.03.02.04.01 1.03.02.04.02 1.03.02.04.03

LINAC 341 1,193 170All areas, except Injector and Undulator

1.04.02.08 Undulator 29 200 57

2.03.02.04.01 2.03.02.04.02 2.03.02.04.03

Contingency 0 94 0Parts needed to ensure success

NA Totals 1,141 1,487 228

Grand Total 2,856

Estimated Cost (k$)


Areas

Areas

Injector, Sector 21 and BC1 – needed for first injection to Tune-up Dump at BC1, field test systems only


Areas - New Systems - Injector, Sector 21 and BC1

Field test 6 new Intermediate and 96 new MCOR systems


Areas - Sector 21 QE System Modification

Bulk PS

Boost PS

Q21201

Q21301

Q21401…

Q21901

SLC Mode

Bulk PS

Boost PS

Q21201

Q21301

Q21401…

Q21901

LCLS Mode

Isolation Switch

Reversing/Shorting Switch


Areas - New Systems Downstream of the Tune-up Dump

Sector 24, BC2, BSY, LTU, Undulator, Dump

32 new Intermediate systems, typically 10kW and 15kW rated

105 new MCOR systems, typically 240W rated (33 of these are in the Undulator under recently added scope)

2 new pulsed kicker systems

27 new and reused racks


Intermediate Power Supplies


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”

Intermediate Power Supply - Front View


Intermediate Power Supply - Rear View

J1 J2

+ -DC Output AC Input

DC Output Cables

TerminalCover

Totally covered connectors


Intermediate PS - Ethernet PS Controller (EPSC)


Intermediate PS - EPSC

PurposeReplaces the PEP 2 Bitbus Power Supply Controller

Provides commonality with the Bitbus Controller

Performance better then the Bitbus Controller 20bit ADC 24bit DAC

Equal to or less expensive then Bitbus ControllerRationale for Replacement

Bitbus DAC obsolete - new DAC required

Bitbus network obsolete - convert to Ethernet (10/100 Mb/sec over UDP)

FPGAs at end of life and not good choices for new designs

8044 processor is obsolete

Use standard +/-15VDC power supply


Intermediate PS - EPSC

FunctionsPrecision current regulation

Readback of current, voltage, and ground current

Ground fault detection and protection

Hardware magnet and power supply protection

Fault latching and reporting

Simple low cost serial communication to central control

Control of power supplies of many ratings, types and from different vendors

Standard cables (Cat 5 UTP and D-sub computer cables)


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

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

Intermediate PS - DC Current Transductors


Intermediate PS - System Architecture

Terminal Server

Network SwitchSLAC

Ethernet PS Controller

Ethernet

OPI

EPICSIOC

Intermediate PSTransductors

Interlocks


The MCOR Systems

• Power 6A, 12A, and 30A correctors, small quadrupoles, and trim magnets that require unipolar or bipolar current

• MCOR6 - 40V, 6A, 240W

• MCOR12 - 40V, 12A, 480W

• MCOR30 – 40V, 30A, 1,200W


The MCOR6 and MCOR12


The MCOR30


MCOR Systems - PLC Uses

Uses

SPEAR 3 experienced MCOR30 bridge MOSFET failures during bulk power supply turn on – need PLC for soft-start

MCORs not provided with ground fault detection. A PLC with external circuitry is needed

MCORs power some magnets that are water-cooled. MCORs are not provided with a Klixon or water flow switch interface. A PLC is needed

Provides bulk power supply remote turn-on and turn-off

Provides bulk power supply output voltage and current monitoring


MCOR System Architecture

OPI OPI

EPICS IOC

VME Crate

Bulk PS

MCOR Gnd Current

Monitor

MCOR12

16 Magnets@12Amps max

MCOR Soft-Start


MCOR VME Controls

Acromag IP231-16E: MCOR DAC (control)Bipolar voltage +/- 10V 16-bit resolution, 16-channels, single-ended

Hytec IP-ADC-8413: MCOR ADC (monitor)Bipolar voltage +/- 10V16-bit resolution, 16-channel, differential

Acromag IP-440-2E DI: MCOR Ground I Monitor (monitor)32-ChannelInput voltage range +/- 16V to +/- 40VOptically Isolated

Acromag IP-445-E DO: MCOR Ground I Monitor (control)32-ChannelVoltage range +/-60VOptically Isolated


MCOR VME Controls Continued

MVME6100 CPU – Power PCTwo Ethernet portsTwo PMC slots

Wiener VME-64X Crate with fan and Ethernet Control

Acromag AVME9670 - 64X IP Carrier (1 per MCOR crate)4 Ports

Acromag Tran-200: Transition Module Install in rear of VME crate4 SCSI-2 Connectors (50-pin)


The Kicker Pulsers

Q D

+

C

CAP

CHARGING

HVPS

DRIVER

ONE-SHOT> 1.5 msec

GND FAULTDETECTION

PULSE CURRENTAMPLIFIER

TRIGGER

CT+

CT-

PULSER CONTROLLER

KICKER PULSER

BXKIKOR

BYKIK

HV REF

HV READBACK

HVPS STATUS


The Kicker Pulsers

BXKIK BYKIK unit

Peak Current 263 263 A

Inductance 0.15 0.6 mH

Resistance 5 20 mΩ

Voltage 150 600 V

PRR 120 120 Hz


The Schedule


Materials CostItem Quantity Cost Each (k$) Extended Cost (k$)

Magnets from Intermediate PS 32 19.9 637

Intermerdiate PS 10 and 15kW 38 8.5 323

Intermediate PS 15kW 14 12.0 168

Power supply controllers 40 2.5 100

Transductors 70 0.7 46

Magnets from MCORs 105 5.9 616

MCOR PS 120 2.0 240

Interface boards, crates,blowers 15 5.0 75

MCOR bulk PS 10 8.5 85

PLC and VME crates 9 24.0 216

Kicker magnets from pulsers 2 72.0 144

Network Switches and Servers 7 3.0 21

Racks, Accessories, Misc Parts 27 2.5 68

Total Cost 1,487


EDI

Person Task Rate (k$/mo) Percent time Duration (mos) Cost (k$)

Management 25% 15 74

Engineering 25% 13 74


Testing 25% 15 74


Testing 15% 15 45

Management 25% 15 70


Programming 25% 13 61

Testing 15% 15 42

Debbie Rogind Programming 18.6 100% 3 56

Coordination 50% 13 90

Programming 15% 11 23

Coordinator Design and purchase 13.8 75% 14 145

Technician Testing 11.1 50% 15 83

1,141

Associate 13.8

Dave MacNair 19.8

Kristi Luchini 18.6

Paul Bellomo 19.8

Antonio de Lira 19.8


Labor – last Slide

Assemble systems into 27 racks and wire8 techs * 4 months * $8.3k/month * 1.34 overhead = $341k

Magnet Controls GroupOctober 4, 2006 1 Scope, Cost Estimate and Schedule To Complete The LCLS Magnet...

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Transcript of Magnet Controls GroupOctober 4, 2006 1 Scope, Cost Estimate and Schedule To Complete The LCLS Magnet...