AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade AIP 67-2901/02 Review LINAC SECTORS 22 AND 23 QE MAGNET POWER SYSTEM UPGRADE Paul Bellomo / Serge Ratkovsky December 6, 2007 controls added by K. Luchini on April 28, 2008 controls cost updated April 21, 2009 December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade

RESTATED SCOPE AND MOTIVATIONS Scope on October 31, 2007 Upgrade “QE” magnet power supplies and controllers in LINAC Sectors 22 and 23 Two new “bulk” power supplies and sixteen new “boost” supplies New Ethernet power supply controllers, new zero flux current transductors, new PPS chassis Motivations Equipment more than 20 years old and at end of useful life. Unreliable, lack of available parts will affect future LINAC operations Better short and long-term current stability Interface with new EPICS-based control system for better diagnostics Lower line harmonics, noise, power consumption December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade

CHANGES SINCE 07/10/31 REVIEW Review Topics Downtime length Two to three bulk power supplies Possible purchase of new rack PPS elimination – use magnet covers Commitment of Controls Department to support this effort December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 3

AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 1. DOWNTIME LENGTH Original and Present Understandings and Plan Issue October 31, 2007 Plan December 6, 2007 Plan Downtime 10 weeks – 10/1 through 12/15/08 4 weeks – 10/1 through 10/31/08 Build plan Refurbish racks and assemble/test in field Purchase new racks and assemble / test in B15 December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 4

2. TWO TO THREE BULK POWER SUPPLIES Mode / PS Type SLC LCLS Bulk 200A 139V 25A 17V Boost 20A 3.7V Change in rating and use of 3 bulk PS: 1. Better match of rating to load (225A – 200A or 25A) in SLC and LCLS modes 2. Less expensive, smaller and COTS December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade

AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade THE EXISTING December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 6

THE REVISED BULK PS TOPOLOGY Bulk power supplies were identified as the critical path item if custom designed – COTS desired December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 7

AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade CONTROL OF 3 PS DIAGRAM Black items are provided by power supply manufacturer\ Red items are provided by SLAC December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 8

3. POSSIBLE NEW RACK PURCHASE The issue is time! A 4 week downtime will not allow for field rack refurbishment, system assembly, and test Two new single bay racks – $4,000 * 2 = $8,000 Cost to refurbish existing racks = 2 racks * 2 techs * 9 days / rack * 1 month / 20 days *$8.5k / month = $15,300 + $500 materials = $15,800 Note: Costs are unburdened and are for comparison purposes only December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade

4. PPS ELIMINATION - USE MAGNET COVERS PPS System Magnet Covers EDI: 1engr*0.5mon*$15.1k/mon + 1coord*0.5mon*$10.5k/mon + 1 tech * 0.5day/chassis * 4 chassis* 1mon/20days * $8.5k/mon = $13.7k EDI: Previously completed M & S: 4 chassis * $5k/chassis = $20k M & S: $300*16 = $4.8k Assembly/Install: 1tech*3 days/chassis *4 chassis *1mon/20days * $8.5k/mon = $4.8k Assembly/Install: 16manhours/cover *16 covers $77.50/hour = $19.8k Total cost: $38.5k Total cost: $24.6k Notes: Costs are unburdened and are shown for comparison purposes Consistency with Sector 20, 21 and 24 magnets December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade 10

5. CONTROLS COMMITMENT – LAST SLIDE Network switch purchase needed Soft IOCs exist Programming support to recognize new systems (operating programs, displays, etc already written) December 6, 2007 AIP 67-2901/02 P Bellomo - QE Magnet Power System Upgrade

for QE Upgrade (per sector) Network Block Diagram for QE Upgrade (per sector) EPICS IOC MCOR Bulk Timing fbck ca crate Upgrade Ethernet Network Switch swh-li23-nw02 Terminal Server ts-li23-nw01 EPSC (lgps) EPSC (Q23201) EPSC (Q23301) EPSC (Q23401) EPSC (Q23501) EPSC (Q23601) EPSC (Q23701) EPSC (Q23801) EPSC( Q23901) 12

Controls Cost Estimate for QE Upgrade (per sector) Software 3-day @ $700/day $2,100.00 Database Displays ChannelWatcher, Archiver, SCORE, Alarm Handler ,LEM , Oracle Hardware Ethernet Switch: 10 ports total (9-epsc, 1-terminal server) $ 0.00 Terminal Server: 9 ports total for epsc $ 1200.00 Intra-rack cables (cat6) $ 1200.00 Total M&S: $ 2,400.00 ED&I $ 650.00 Labor $ 1000.00 Total Hardware: $ 4,450.00 Total Software: $ 2,100.00 without Burden and Contingency Total: $ 6,650.00 Contingency 10% of M&S: $ 445.00 Burden 30% of M&S: $ 1335.00 with Burden and Contingency:: $8,430.00 13

Controls Cost Estimate for MCOR Upgrade (per sector) Software Database & Displays 1.5 day $ 700.00 ChannelWatcher, Archiver,SCORE, Alarm Handler, LEM 0.5 day $ 350.00 Checkout (does not include cost of pcd engineer and pcd tech) 3-days $2,100.00 5-days @ $700/day Total : $3,500.00 Hardware (per sector) 3U Elma VME Crate (4-slot) $ 3200.00 EVR PMC Module $ 2000.00 MVME6100-0161 CPU (1 per sector, existing) $ 4000.00 Timing Cables $ 1000.00 Terminal Server: 1 port total for ioc $ 0.0 Ethernet: 3ports total (1-crate,1-ioc,1-fbck) $ 0.0 Intra-rack cables (cat6 and mcor to vme) $ 150.00 Acromag IP Carrier AVME9670 w/P0 $ 700.00 Hytec IP-ADC-8413 +/-10V, 16-bit, 16-chan adc $2500.00 Acromag ip231-16E +/-10V, 16-bit,16-chan dac $1375.00 Acromag Trans 200 Transition module $ 275.00 Total M&S: $15,200.00 ED&I Drawings $ 500.00 Labor $ 1000.00 Total Hardware: $16,700.00 Total Software: $ 4,450.00 without Burden and Contingency Total: $ 21,150.00 Contingency 10% of M&S: $ 1,520.00 Burden 30%of M&S: $ 4,560.00 with Burden and Contingency Total: $ 27,230.00 14

Total Cost QE’s and MCOR Upgrade Cost including burden and contingency QE Upgrade with Burden and Contingency $ 8,430.00 MCOR Upgrade with Burden and Contingency $ 27,230.00 Total cost per sector: $ 35,660.00 Total cost for 8 sectors: $285,280.00 Cost without burden and contingency QE Upgrade $ 6,650.00 MCOR Upgrade $ 21,150.00 Total cost per sector: $ 27,800.00 Total cost for 8 sectors: $222,400.00 Note: optional use of an mvme3100-1263 cpu and MVME721-101 with transition module will reduce the cost by $1,700.00. 15

VME Crate and I/O Front View Rear View Trans 200 Port D Port C Port B 4 3 2 1 Slot Trans 200 Port D Port C Port B Port A 4 3 2 AVME9670 1 Debug Lan 1 Lan 2 E V R P M C MVME 6100 Slot 16

VME I/O CPU with Event (Timing) 17

VME I/O For MCOR Control and Monitor 18