1. SC1R Cold Box PDR Controls
SC1R Cold Box Preliminary Design Review
R Norton
Thursday, November 08, 2018

2. General Controls Overview
Power for the new system
Removal of existing cables and transformers
New Breaker panel instead of a breaker ‘box’
Power for pump on secondary CW loop.
Controls for the new system
PLC system already exists for this purpose.
Some new wiring
Controls for new secondary CW loop
Instrumentation for the new system
Pressure transducers, feedthroughs, and tubing.
SC1R PDR Controls

3. Control System Overview
Vendor (x5)
EPICS System
Control Cabinet
(AMB/VFD)
Motor
Cold Compressor
Magnetic Bearings
Temperature Sensor
Speed Sensor
EPICS OPI
EPICS
Servers
Cryo Controls Network Switch
EPICS IOCs
2K Coldbox
PLC
Power
120V (UPS/Normal)
Instrumentation
(Sensors, Valves, etc.)
Digital Comms Gateway
480V/3PH)
Hardwired
Signals
Stop, Start
40 AMPS
SC1R PDR Controls

4. Existing Power Overview
Power Feed
CC1-4
480V/3PH)
Power Feed CC5
480V/3PH)
100A
V XFRMR
V XFRMR
30A
100A
Breaker Box
35A
100A
60A
VFD 1
AMB1
VFD 2
AMB2
VFD 3
AMB3
VFD 4
AMB4
VFD 5
AMB5
XFRMR
XFRMR
XFRMR
CC1
CC2
CC3
CC4
CC5
SC1R PDR Controls

5. Future Power Overview Breaker Panel Power Feed CC1-5 480V/3PH) 100A
AMB/VFD 1
AMB/VFD 2
AMB/VFD 3
AMB/VFD 4
AMB/VFD 5
CC1
CC2
CC3
CC4
CC5
SC1R PDR Controls

6. Existing Controls Hardware To Be Reused
Allen-Bradley ControlLogix 1756 PLC for cold box control.
Takes in digital and analog I/O data
Control for valves and CC remote stop signals
Interface to remote display screens,
Redundant 24V and PLC power supplies
Fed by EM-loop and house power
Backed up by a UPS
Temperature diode signal conditioning
Two 8-Channel Cryocon temperature monitors
Ethernet connection to PLC.
Vacuum control enclosure
Diffusion Pump Heater and Gate Valve control based on foreline and Box pressure.
SC1R PDR Controls

7. New Controls Hardware Required
Cold Compressor Frequency Drive and Magnetic Bearing Enclosure
Supplied by the Cold Compressor vendor
Instrumentation junction box
Pressure transducers
Temperature terminals for primary/spare management
Control enclosure for secondary cooling water loop pump and valve
Control for solenoid valve and pump.
Automatically engages solenoid valve based on a differential pressure switch.
SC1R PDR Controls

8. Control Logic 2K system control loops remain the same.
One primary PID loop for CC1-4 speed. Individual CC speeds are set by a software ‘gear ratio’ to this master speed command.
Follow a pre-established pump down sequence that varies gear ratios
PID loop that varies CC5 speed in order to control CC5 suction pressure.
CC5 optionally can be set to have a gear ratio to the master speed, as is done for the other 4.
Safety shutdown hardwired from PLC digital output directly to the VFD/Mag Bearing
Allows PLC to shutdown or inhibit VFD from starting motor in the event the Digital communications interface fails
A problem with one cold compressor will make the PLC shut them all down along with outlet valves.
SC1R PDR Controls

9. The vendor will provide a suitable path.
Pumpdown Path
A ‘path’ must be found to pump down the system from 1 atm to ~.035 atm.
This involves varying the ratio of the cold compressors with the pressure as it comes down.
The vendor will provide a suitable path.
Some experimentation and commissioning time will be required to perfect.
SC1R PDR Controls

10. Cold Compressor Software Interface
Digital Communications Between the PLC and motor controller/Magnetic Bearings
Loss of communications should result in a trip
Vendor must provide a communication signal list with sufficient breadth:
Speed readback
Speed command
Motor/Bearing faults and status
Mag bearing unbalance/current information
Temperature status information
SC1R PDR Controls

11. Electrical Cabinet Considerations
Control cabinets should be located within 10 m from motors to accommodate maximum cable length
Control cabinets should handle both Magnetic Bearing and VFD functionality.
Control cabinets will likely not require any UPS backup, with a standard now to use the regenerated power from the wheel to power magnetic bearings in the event of power outages
SC1R PDR Controls

12. Controls Engineering Work Required
PLC Wiring details
Instrumentation panel layout
Controls Cable routing (rework of existing cable tray)
Power Cable routing
Power distribution details for 480V
Tubing schematics for instrumentation
PLC programming
Secondary Cooling Water Loop Controls
Most of these items can be copied from the LCLS2 project.
SC1R PDR Controls

13. R Norton
(757) ,
Thursday, November 08, 2018