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

2. 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 /02 P Bellomo - QE Magnet Power System Upgrade

3. 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 /02 P Bellomo - QE Magnet Power System Upgrade 3

4. 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 /02 P Bellomo - QE Magnet Power System Upgrade 4

5. 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 /02 P Bellomo - QE Magnet Power System Upgrade

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

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

8. 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 /02 P Bellomo - QE Magnet Power System Upgrade 8

9. 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 /02 P Bellomo - QE Magnet Power System Upgrade

10. 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 /02 P Bellomo - QE Magnet Power System Upgrade 10

11. 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 /02 P Bellomo - QE Magnet Power System Upgrade

12. 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

13. Controls Cost Estimate for QE Upgrade (per sector)
Software $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) $
Terminal Server: 9 ports total for epsc $
Intra-rack cables (cat6) $
Total M&S: $ 2,400.00
ED&I $
Labor $
Total Hardware: $ 4,450.00
Total Software: $ 2,100.00
without Burden and Contingency Total: $ 6,650.00
Contingency 10% of M&S: $
Burden 30% of M&S: $
with Burden and Contingency:: $8,430.00 13

14. Controls Cost Estimate for MCOR Upgrade (per sector)
Software
Database & Displays day $
ChannelWatcher, Archiver,SCORE, Alarm Handler, LEM 0.5 day $
Checkout (does not include cost of pcd engineer and pcd tech) 3-days $2,100.00
$700/day Total : $3,500.00
Hardware (per sector)
3U Elma VME Crate (4-slot) $
EVR PMC Module $
MVME CPU (1 per sector, existing) $
Timing Cables $
Terminal Server: 1 port total for ioc $
Ethernet: 3ports total (1-crate,1-ioc,1-fbck) $
Intra-rack cables (cat6 and mcor to vme) $
Acromag IP Carrier AVME9670 w/P0 $
Hytec IP-ADC /-10V, 16-bit, 16-chan adc $
Acromag ip231-16E +/-10V, 16-bit,16-chan dac $
Acromag Trans 200 Transition module $
Total M&S: $15,200.00
ED&I Drawings $
Labor $
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

15. 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, Total cost per sector: $ 27, Total cost for 8 sectors: $222,400.00
Note: optional use of an mvme cpu and MVME with transition module will reduce the cost by $1, 15

16. VME Crate and I/O Front View Rear View Trans 200 Port D Port C Port B4 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

17. VME I/O CPU with Event (Timing)17

18. VME I/O For MCOR Control and Monitor18