January 12, 2006 ATF2 DC Magnet Power Supplies1 Paul Bellomo and Briant Lam

January 12, 2006 ATF2 DC Magnet Power Supplies2 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

January 12, 2006 ATF2 DC Magnet Power Supplies3 TermDefinition AvailabilityMTBF / (MTBF+Time to repair) MTBFMean 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 NNumber of bulk power supplies mMinimum number of power modules needed for operation nNumber of power modules in a system m=1/n=2One out of two redundant power module configuration m=2/n=3Two out of three redundant power module configuration m=3/n=4Three out of four redundant power module configuration m=4/n=5Four out of five redundant power module configuration DroopOutput voltage decrease with increasing load Glossary of Terms

January 12, 2006 ATF2 DC Magnet Power Supplies4 Phase 1 – Preliminary Power Supply List (For Phase 2)

January 12, 2006 ATF2 DC Magnet Power Supplies5 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

January 12, 2006 ATF2 DC Magnet Power Supplies6 Phase 1 - Typical System Block Diagram

January 12, 2006 ATF2 DC Magnet Power Supplies7 Phase 1 – Availability Improvement by Parts Reduction and Module Redundancy

January 12, 2006 ATF2 DC Magnet Power Supplies8 Simple Rectifier Bulk Supply 6 or 12 pulse Transformer matches line V to load V. 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

January 12, 2006 ATF2 DC Magnet Power Supplies9 Elgar Electronics Corporation 9250 Brown Deer Road San Diego, CA Website: IE Power 12 Falconer Drive, Unit 15 Mississauga, Ontario Canada L5N 3L9 Lambda-EMI Aroma Square Bldg 5F Kamata, Ohta - Ku Tokyo Japan Matsusada - Shiga Headquarters 745 Aoji-Cho, Kusatsu -City, Shiga, Japan Phase 1 - Bulk Power Supply Manufacturers

January 12, 2006 ATF2 DC Magnet Power Supplies10 Phase 1 – Power Module Buck Regulator Topology

January 12, 2006 ATF2 DC Magnet Power Supplies11 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

January 12, 2006 ATF2 DC Magnet Power Supplies12 Phase 1 – Democratic Current Share Circuitry

January 12, 2006 ATF2 DC Magnet Power Supplies13 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

January 12, 2006 ATF2 DC Magnet Power Supplies14 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 Supplies15 GMW Associates 955 Industrial Road San Carlos, CA Hakuto Company Ltd. Scientific Equipment Department, 1-13, 1-chome, Shinjuku, Shinjuku-ku, Tokyo 160, Japan Tel Phase 1 - Current Transductor 0.3 ppm / O C Purpose Monitors output current for use in regulation loop Monitors current for system display and histograms

January 12, 2006 ATF2 DC Magnet Power Supplies16 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 15% $19k/month$14,000 1 Technician for 5 10% $11k/month$5,500 Labor total$19,500 Total cost$29,000

January 12, 2006 ATF2 DC Magnet Power Supplies17 Phase 1 - Schedule and Status

January 12, 2006 ATF2 DC Magnet Power Supplies18 Phase 2 - Configuration of 41 Systems Assumes racks are available and suitable for use as depicted – Brown modules, Blue spares

January 12, 2006 ATF2 DC Magnet Power Supplies19 Phase 2 - Cost Estimate

January 12, 2006 ATF2 DC Magnet Power Supplies20 Phase 2 - Schedule

January 12, 2006 ATF2 DC Magnet Power Supplies21 Phase 3 – Recommended Spare Parts Item System Quantity Recommended Spares Quantity Spares Cost k$ Bulk/Dipole power supplies Power supply crates Power supply modules Ethernet controllers Transductors Intra-rack cables Total spares cost38.3

January 12, 2006 ATF2 DC Magnet Power Supplies22 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

January 12, 2006 ATF2 DC Magnet Power Supplies23 Phase 3 - Schedule

January 12, 2006 ATF2 DC Magnet Power Supplies24 Phase 3 - Costs

January 12, 2006 ATF2 DC Magnet Power Supplies25 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% $ %

January 12, 2006 ATF2 DC Magnet Power Supplies26 Discussion Issues and Closing Slide SLAC provides fully assembled racks with internal AC distribution – this will reduce installation and travel costs. Thank you!