Electrical and Controls Chris Scanlon LCLS-II 2K Cold Box FDR March 9, 2017

Outline Electrical Overview Cold Compressors Controls Overview Alarms Control Loops Cold Box Trips Interlocks Sequences Documentation LCLS-II 2 K CBX FDR, Mar 9, 2017

Overview LCLS-II 2 K CBX FDR, Mar 9, 2017

6 x 35A 480V ac 3 phase circuits for cold compressors Electrical Overview 6 x 35A 480V ac 3 phase circuits for cold compressors 2 x 20A 120V ac single phase circuits for control box One from house power One from emergency power (UPS and generator backup) Routed in conduit Motor and bearing cables routed in cable tray Control cabinets to be located within 10m from motors to accommodate maximum cable length LCLS-II 2 K CBX FDR, Mar 9, 2017

Six differently sized centrifugal cold compressors Two motor sizes One high speed, one low speed Six identical cold compressor control cabinets Each contains an identical combination magnetic bearing controller and motor drive (Mecos MMC15) Hardwired stop and fault signals CANopen communications for speed command/readback, faults, warnings, etc Designed with seismic bracing LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold Compressor CAN Signals Name Can Addr Access Datatype Description Unit Speed SP 2000h R/W int16 Speed Setpoint. Cannot be beyond max speed Hz Current Speed 2001h R Current Speed of motor Run/Stop 2009h bit 1 to Start, 0 to Stop the drive   Drive Enable 200Bh Set bit 1 to enable the dive control via CAN Bus Floating 200Ch Bit is set to 1 by the firmware if the system is floating System Status: Initializing 2025h Indicates that the system is starting up and initializing (1) or ready (0) Motor Temp 2003h Temperature of the motor; Limit: 200 internal units for all motors except No.1 where its 150 units. Sensor is PTC Internal Units (IU) Mains Hours 3004h int32 Indicates the number of hours the system was switched on Hrs Floating Hours 3005h Indicates the number of hours the system was floating Rotating Hours 3006h Indicates the number of hours the system was rotating Approx. Set Point Force Z Bearing 2405h Approx. SP force to the axial bearing in internal units Divide by #12 to get a relative value of the bearing load IU Approx. SP Force Z Bearing Trip Limit 240Bh If the Sp force (#11) of the axial bearing is beyond this limit an error occurs and the system gets tripped. 900N~4095 Internal units Approx. Set point Force Z Bearing Maximal Value 2425h Max SP force (abs value) of the axial bearing. This value measures the peak. After reading this value, you have to overwrite this value with a ‘0’ to reset actual peak value(drag indicator). Divide #12 for relative value of bearing load Unbalanced Values A Bearing 2026h 32 bit Array Square of the unbalanced value on the A bearing. If this value is beyond the limit (#20^2) an error occurs B Bearing Square of the unbalanced value on the B bearing. If this value is beyond the limit (#21^2) an error occurs Reset Faults 200Eh W Set bit to 1 to clear fault Error Status 2020h 16 bit Array Errors and warnings, see also sheet Error list SlfChkFlt 2021h Self Check Faults, see also sheet Error list Sys Status Rotating 3FFFh Bit 1 of 16 Bit Array (from Bit0-15)(Bit 0 = Floating, Bit 1 = Rotating) Unbalanced / Orbit limit value Bearing A 2027h Unbalanced Value limit on the A bearing Unbalanced / Orbit limit value Bearing B Unbalanced Value limit on the B bearing LCLS-II 2 K CBX FDR, Mar 9, 2017

PLC controlled system Variables shared with other systems Controls Overview PLC controlled system Dedicated Allen Bradley L81 processor Same processor manufacturer/generation as CDS/CMs Ethernet communications to temperature diode transmitters, EPICS and other PLC systems CANopen to Ethernet gateway for cold compressors Variables shared with other systems CM heater request CM JT PID LL set point DB HX bypass valve DB linac supply valve LCLS-II 2 K CBX FDR, Mar 9, 2017

Local HMI for local, manual operation I/O count Controls Overview Local HMI for local, manual operation I/O count 35 digital inputs, 29 spares 23 digital outputs, 9 spares 19 analog inputs, 13 spares 8 analog outputs, 8 spares 13 temperature diodes, redundant pairs, 7 spare inputs High accuracy (0.04%) pressure transducers Better evaluation of cold compressor efficiency LCLS-II 2 K CBX FDR, Mar 9, 2017

Return pressure from linac Return temperature from linac Alarms Flow to 4K cold box Return pressure from linac Return temperature from linac Fifth CC outlet pressure Fifth CC outlet temperature Insulating vacuum Flow surge From cold compressors Power supply failure PLC card failure LCLS-II 2 K CBX FDR, Mar 9, 2017

2 active during pump down and 2K operation Control Loops 8 control loops 2 active during pump down and 2K operation Fourth cold compressor speed control based on flow Fifth cold compressor speed control based on inlet pressure LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold Box Trips 18 trip points 3 surge trips CANbus failure Flow is 5% less than set point Flow rate change is too high Pressure spike at linac CANbus failure Process Variable Trip Level Effect PT 41160H > 2 atm 2K cold box trips PT 41150H FD41100 FB41100 PV41160R < 95% PV41170R LCLS-II 2 K CBX FDR, Mar 9, 2017

Interlocks Interlocks Opening outlet valves Starting cold compressors Magnetic bearings levitating without faults Pressure difference on both sides of valves < 0.06 atm Instrument air pressure to valves Starting cold compressors Mag bearings levitating without faults Inlet pressure > 1.05 atm Outlet valves open Surge alarm cleared LCLS-II 2 K CBX FDR, Mar 9, 2017

Sequences Backfill sequence Pump down sequence Backfill valve controls so 4K cold box LP pressure doesn’t drop below 1.08 Valve closes when linac reaches 1.1 atm Pump down sequence Preparation Open outlet valves Start cold compressors, set gear ratios, fifth CC PID set point, fourth CC min and max Open CM JTs for 120 seconds to cool down Pump down Steps governed by 2K cold box inlet pressure Command JT PID liquid level set point Set flow set point of fourth CC PID Send DB HX bypass valve position to increase density of CC gas Control DB linac supply valve based on line A pressure into DB Request heat from CM heaters Transition to steady state After inlet pressure is 0.028 atm, set flow of fourth CC PID to 200 g/s Ramp gear ratios of first to third CCs to steady state value LCLS-II 2 K CBX FDR, Mar 9, 2017

Cold Box Trip Sequence Outlet valves close Prevent reverse flow of gas Minimize linac pressure Reduce forces on cold compressors Cold compressors commanded to stop Linac liquid level commanded to 75% Closes JT valves Maintain minimum linac pressure LCLS-II 2 K CBX FDR, Mar 9, 2017

Documentation Document No. Title Author Status 79222-1000 to 1012 LCLS-II 2K Cold Box Control System Drawings T. McCool Jlab review 79120-1910 LCLS-II Cryogenics Building Electrical Distribution JLab Scope A. De Lira Released LCLS-II-4.8-EN-0768 Cryogenics Plant 2K Cold Box Software Specification C. Scanlon JLab review 79222-C7001 LCLS-II 2K Cold Box System-Instrument List LCLS-II 2 K CBX FDR, Mar 9, 2017

Summary Electrical design is mature and released Controls hardware and software design Alarms, trips, interlocks, control loops are the same as JLab and FRIB Incorporate JLab’s 20+ years of experience Cold compressor magnetic bearings experience no wear during normal operation Software minimizes upsets to cold compressor train LCLS-II 2 K CBX FDR, Mar 9, 2017