1. LCLS-II 2K Cold Box Controls Design Review
JLab
27 September 2016
2K Cold Box Design Review 24 Aug 16

2. Charge 7: Instrumentation & Controls
Is the electrical & controls design of the system sound?
Process control
Control system, devices/instruments
Electrical power
2K Cold Box Design Review 24 Aug 16

3. Instrumentation & Controls
Control System Overview
Vendor (x5)
Control System
Control Cabinet
Motor Drive
Mag Bearing Controller
Motor
Cold Compressor
Magnetic Bearings
Temperature Sensor
Speed Sensor
EPICS OPI
EPICS
Servers
Cryo Controls Network Switch
EPICS IOCs
2K Coldbox
PLC
PanelView
Power
120V (UPS/Normal)
Instrumentation
(Sensors, Valves, etc.)
CANbus
Gateway
(480V/3PH)
Hardwired
Stop, Cabinet Temp
2K Cold Box Design Review 24 Aug 16

4. Instrumentation & Controls
Allen Bradley ControlLogix architecture as with all other SLAC Cryoplant systems
Dedicated PLC and touch screen for 2K Coldbox
Redundant power feeds (UPS and Normal), 24VDC, and PLC power supplies
2K Cold Box Design Review 24 Aug 16

5. Instrumentation & Controls
Cold compressors control loops same as JLAB
One primary PID loop for speed. All CC speed commands are dependent on this PID loop with a variable software gear ratio.
Follow a pre-established pump down sequence that varies gear ratios, which will be established at FDR.
Vacuum systems similar to 4K CBX
Test heater controller (3kW) with integrated SCR controls and power measurement feedback
2K Cold Box Design Review 24 Aug 16

6. Instrumentation & Controls
CC Hardware/Safety Interface
Safety shutdown hardwired from PLC digital output directly to the motor drive
Allows to shutdown or inhibit drive from starting motor directly from PLC in the event the CANbus interface fails
Cabinet over-temperature
Fan controller fault to be wired to PLC
Allows to monitor if temperature rises 10C above setpoint inside VFD cabinet
Local cabinet indicators
Error, Levitated, Rotating, Cabinet power ON
2K Cold Box Design Review 24 Aug 16

7. Instrumentation & Controls
CC Software interface
VFD Interface is CANbus and requires a Gateway to communicate to PLC.
Vendor provides CANbus communication. SLAC will procure a CANbus to Ethernet/IP gateway for direct communications to PLC hardware.
Vendor utilizes Siemens PLCs and SLAC uses Allen Bradley ControlLogix.
Program listing and additional information was requested and obtained from vendor to allow porting the Siemens interface program to Allen Bradley.
2K Cold Box Design Review 24 Aug 16

8. Instrumentation & Controls
CANbus Parameter List
2K Cold Box Design Review 24 Aug 16

9. Instrumentation & Controls
Electrical
Electrical wiring for cold compressor controls (Drive/AMB) have not yet been reviewed
Once reviewed, requested changes will be asked of vendor
Control cabinets to be located within 10 m from motors to accommodate maximum cable length
2K Cold Box Design Review 24 Aug 16

10. Instrumentation & Controls
Electrical
All motor controls will have the same power requirements
Temperature and pressure sensors will be standard JLab design
4K operation will utilize a bypass valve in the cold box
2K Cold Box Design Review 24 Aug 16

11. Instrumentation & Controls
Identified risks
No access to VFD parameters
Mitigation:
Vendor support during commissioning
Vendor to provide memory cards with combination of configurations to allow updates to VFD parameters
CANbus interface implementation
Procure spare VFDs ahead of schedule to allow time for development and testing of interface
2K Cold Box Design Review 24 Aug 16

12. Remaining Elec. & Cont. Work
Design of PLC enclosure, heater control enclosures, vacuum controls, instrument panels, and temperature layout and feedthroughs.
2K Cold Box Design Review 24 Aug 16

13. Summary
The LCLS-II 2K CBX incorporated all the lessons learned in design, commissioning and operation over the last two decades on the three similar systems at JLab & SNS
The operational range is extended without exposing the project to higher risk
The design goal is to achieve the highest pressure stability and system efficiency
2K Cold Box Design Review 24 Aug 16