1. Paul Bellomo LCLS Power Suppliesbellomo@slac.stanford.edu March 30, 2006 1 LCLS Injector, Sector 21 and BC1 New Power Supplies Needed for First Injection P. Bellomo

2. Paul Bellomo LCLS Power Suppliesbellomo@slac.stanford.edu March 30, 2006 2 List of Needed Magnet Power Supplies Refer to the list in the binder Intermediate Power Supplies 6 dipole and quadrupole magnets require 8 power supplies 13 on order, 1 contingency of each type MCOR12 Power Modules 72 corrector, quadrupole and trim magnets require 72 power supplies 75 on order, 3 are contingency MCOR30 Power Modules 12 corrector, quadrupole and trim magnets require 12 power supplies 20 on order, 8 contingency MCOR Bulk Power Supplies 3 needed, 3 ordered, 0 contingency

3. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 3 Intermediate Power Supplies

4. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 4 Output V, I and PAt least 10% greater than magnet standardize value Short term stability100 ppm RMS, 1 second, Long term stability100 ppm RMS, 10 seconds at 30C Stability versus temp  2 ppm / O C – 10 to 100% Ambient40 O F (4 O C) to 113 O F (45 O C) Bandwidth as V source DC to – 3 dB  1,000Hz Bandwidth as I source DC to – 3dB  10Hz Conducted EMC / Life/ MTBF FCC, Part 15, Class A  20 years  100,000 hrs Load 0.05H  L  1.0H, 0.1 s  L/R  1.0 s Performance Requirements

5. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 5

6. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 6 Inputs to Power Supply from Controller On/OffDiscrete, continuous+5V On, 0V Off Programming VoltageAnalog, continuous0 to +5V, 0 to FSV or 0 to FSI ResetDiscrete, momentary+5V 100ms pulse Outputs from Power Supply to Controller On/Off StatusDiscrete, continuous0V On. +5V Off PS Ready - sum of internal faultsDiscrete, continuous0V ready, +5V not ready Output currentAnalog, continuousFrom transductors – not from PS Output voltageAnalog, continuous0 to +10V, 0 to FSV Ground currentAnalog, continuous0 to +10V, 0 to 100mA Interface

7. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 7 IE Power, Incorporated 12 Falconer Drive, Unit 15 Mississauga, Ontario Canada L5N 3L9 905-813-8900 iepower@iepower.com 2.5 kW to 22.5 kW 208 V / 480 V input Series and parallelable 27cm H*48cm W*61cm D 8.74” * 19” * 24” Power Supply - Front View

8. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 8 Power Supply - Rear View Totally covered connectors

9. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 9 Current Transductors

10. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 10 GMW Associates 955 Industrial Road San Carlos, CA 94070 650-802-8292 ian@gmw.com  +/- 150A or +/- 600A  Accuracy < 2ppm  Linearity < 1ppm  0.3 ppm / C  Bandwidth 100kHz DC Current Transductors

11. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 11 Intermediate PS Hazard Analysis EnergyHazardMitigation Electrical  Arc flash at input circuit breaker  Shock 480VAC, 650VDC, 200VDC  PAB = 1 inch  Stored PS and magnet energy < 20kJ  FPB = 3.7 inches  Category 0 PPE, 00 gloves  Bleeder resistors, ground hooks across filter capacitors, 00 gloves, safety glasses  Totally enclosed chassis  Totally covered PS/magnet terminals  Listed components when possible  EEIP Inspection at SLAC  JHAM and STA qualified workers FireTeaspoon amounts of flammable oil in electrolytic filter capacitors Not required. Other components are non-flammable or fire retardant Gravity100lb chassisTwo workers lift with mechanical assistance. Pressure Radiation NoneNot applicable TemperatureHot chassis/components (100 O C)Warning labels on components

12. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 12 Hazard Analysis

13. Paul Bellomo LCLS Intermediate Power Supplies bellomo@slac.stanford.edu March 30, 2006 13 Status Summary Systems Controls established - EI diagrams made to 85% level Power Supplies All here by April 15 Inspection and bench testing April 15 through April 30 Transductors All here and bench tested Remaining tasks Identify cables from the Ethernet switches and terminal servers to the power supply controllers

14. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 14 MCOR Powered Systems with Special thanks to Fernando Rafael

15. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 15 Uses and Requirements Uses Power 6A, 12A, and 30A correctors, small quadrupoles, and trim magnets that require unipolar or bipolar current Output V, I and PAt least 10% greater than magnet standardize value Short term stability30 ppm RMS, 1 second, Long term stability400 ppm RMS, 10 second at 30C Stability versus temp  13 ppm / O C, 10 to 100% Ambient40 O F (4 O C) to 113 O F (45 O C) Bandwidth as I source XC04, YC04, XC07, YC07 DC to – 3dB  10Hz Load 0.05H  L  1.0H, 0.1 s  L/R  1.0 s

16. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 16 The MCOR System

17. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 17 The MCOR12

18. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 18 The MCOR30

19. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 19 MCOR Bulk PS Rating Determination

20. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 20 Inputs from Controller to Each Module Inhibit (1 for all 16 modules)Discrete, TTL, continuous0V = On, +5V = Inhibit Programming VoltageAnalog, continuous-10V to +10V, -FSI to +FSI Reset (1 for all 16 modules)Discrete, TTL, momentary Reset on +5V rising edge, 0V otherwise Outputs from Each Module to Controller Output current (feedback)Analog, continuous-10V to +10V, -FSI to +FSI Output current (monitor)Analog, continuous-10V to +10V, -FSI to +FSI Module FaultDiscrete, continuous0V = no fault, +5V = fault MCOR12 Module Interface

21. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 21 Inputs from Controller to Each Module Inhibit (1 for all 16 modules)Discrete, TTL, continuous0V = On, +5V = Inhibit Programming VoltageAnalog, continuous-10V to +10V, -FSI to +FSI Reset (1 for all 16 modules)Discrete, TTL, momentary Reset on +5V rising edge, 0V otherwise Outputs from Each Module to Controller Output current (feedback)Analog, continuous-10V to +10V, -FSI to +FSI Output current (monitor)Analog, continuous-10V to +10V, -FSI to +FSI Output voltage (+ line)Analog, continuous-10V to +10V, -FSV to +FSV Output voltage (- line)Analog, continuous-10V to +10V, -FSV to +FSV Module FaultDiscrete, continuous0V = no fault, +5V = fault MCOR30 Module Interface

22. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 22 MCOR Hazard Analysis EnergyHazardMitigation Electrical  Arc flash at input circuit breaker  Shock 480VAC, 650VDC, 60VDC in bulk PS and modules  PAB = 1 inch  Stored and magnet energy < 1kJ  FPB = 1 inch  Category 0 PPE, 00 gloves  Bleeder resistors across filter capacitors, 00 gloves, safety glasses  Totally enclosed chassis  Totally covered PS/magnet terminals  Listed components when possible  EEIP Inspection at SLAC  JHAM and STA qualified workers FireTrace amounts of flammable oil in electrolytic filter capacitors in bulk PS Not required. Other components are non-flammable or fire retardant Gravity100lb chassisTwo workers lift with mechanical assistance. Pressure Radiation NoneNot applicable TemperatureHot chassis/components (100 O C)Warning labels on components

23. Paul Bellomo LCLS MCOR Power Supplies bellomo@slac.stanford.edu March 30, 2006 23 Status Power Supplies – MCORs 75 of 75 MCOR12s received and bench tested 20 of 20 MCOR30s received and bench tested 9 crates not yet received – due in April 9 crate blowers are here Most connectors are here 3 bulk power supplies received and bench tested Remaining Tasks Identify MCOR to VME crate cable types, configurations and connectors

24. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 24 MCOR Ground Current Monitor

25. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 25 MCOR Ground Current Monitor Purpose MCOR system does not include ground current monitoring Indicate when power supply current is straying outside magnet Ramifications Monitored MCOR current is not the magnet current Loss of magnet current causes beam problems Ground current fluctuates causing erratic magnet current Requirements Turn off bulk on excessive ground current Display ground current on local display Separate Injector/Sector 21 and BC1 systems Reference Drawings EI-380-201-31, Schematic Diagram and Chassis Layout

26. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 26 Ground Current Monitor Concept

27. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 27 Signal Conditioner and  PLC Dataforth DSCA31-06IDEC Smart Relay

28. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 28

29. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 29 Inputs to Ground Current Monitor from Computer On/Off Command - Bulk PS 1, 2 or 33 Discrete, momentary+24V=On, 0V=Off Remote Reset - Bulk PS 1 & 21 Discrete, momentary+24V=Reset Remote Reset - Bulk PS 31 Discrete, momentary+24V=Reset Inputs to Ground Current Monitor from Other Places Ground I from Bulk PS 1, 2 or 3 resistors3 Analog, continuous0 to +10V = 0 to 100mA Local chassis Reset button, Bulk PS 1, 2, 31 Discrete, momentary+24V=Reset Local chassis Test button, Bulk PS 1,2,31 Discrete, momentary+24V=initiates fault Outputs from Ground Current Monitor to Computer On/Off Status - Bulk PS 1, 2 or 33 Discrete, continuous+24V=On, 0V=Off On/Off/Fault Status - Bulk PS 1, 2 or 3Serial digital data (future)Via Ethernet module Ground Current - Bulk PS 1, 2 or 3Serial digital data (future)Via Ethernet module Outputs from Ground Current Monitor to Others On/Off Command to Bulk PS soft start 1, 2 or 3 3 Discrete, continuous Contact, closed=On, open = Off Ground Current Monitor Interface Requirements

30. Paul Bellomo LCLS Ground Current Monitor bellomo@slac.stanford.edu March 30, 2006 30 Ground Current Monitor Status and Remaining Tasks Schematic diagrams completed, but needs redrawing Job Shopper Designer on board Chassis drawing completed but needs redrawing Job Shopper Designer on board Software for microPLC written, but needs revision Parts ordered and received (except for chassis) Fabrication not yet started Identify all interconnecting cables and connectors

31. Paul Bellomo LCLS Bulk PS Soft-Start bellomo@slac.stanford.edu March 30, 2006 31 MCOR Bulk Power Supply Soft-Start (Courtesy of Fernando Rafael)

32. Paul Bellomo LCLS Bulk PS Soft-Start bellomo@slac.stanford.edu March 30, 2006 32 MCOR Soft-Start Problem SPEAR 3 experienced MCOR30 bridge MOSFET failures during bulk power supply turn on It was determined that, with a fixed front panel controlled set-point, the bulk power supply output voltage was rising too quickly. The MCOR crate auxiliary power supply oscillated Solution and Requirements Soft-start circuit to slowly apply the bulk power supply set-point (and hence ramp the output voltage) after bulk power supply turn on.

33. Paul Bellomo LCLS Bulk PS Soft-Start bellomo@slac.stanford.edu March 30, 2006 33 MCOR Soft-Start

34. Paul Bellomo LCLS Bulk PS Soft-Start bellomo@slac.stanford.edu March 30, 2006 34 MCOR Soft-Start Status and Remaining Tasks Drawings Schematic diagram and chassis drawings completed PCB layout is needed Cables and connectors need specification Parts Electronic and chassis parts are here Need to purchase PCB Fabrication Chassis and PCBs are not yet started Testing Not started

35. Paul Bellomo LCLS Bulk PS Soft-Start bellomo@slac.stanford.edu March 30, 2006 35 Ground Current Monitor and Soft-Start EnergyHazardMitigation Electrical  Shock 120VAC in chassis  Listed components when possible  EEIP Inspection at SLAC  JHAM and STA qualified workers FireNone  Not applicable GravityNoneNot applicable Pressure Radiation Temperature NoneNot applicable

36. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 36 Power Supply Racks

37. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 37

38. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 38 Rack Requirements References Specification ESD 1.2-154, R0 Seismic Document Drawings (later from Optima) Electrical Requirements Keep personnel from inadvertent contact – shock and arc flash Accept AC power and controls interfaces Maintain ground continuity Be reasonably EMI – proof Mechanical Requirements Carry weight of installed components – 1000 lbs per bay Seismic capable Neatly contain equipment Ventilated so that equipment does not overheat

39. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 39 Seismic Requirements Reference: I-720-0A24E-002, Specification for Seismic Design of Buildings, Structures, Equipment and Systems at SLAC, December 4, 2000 Item 6, Page 9 – Rack is defined as Programmatic Equipment H & V Floor Response Spectra Page 6, Fig 3 and Page 7, Fig 4 for Mechanical Systems Table 12 – Performance Level 6.5 to 8.5 – Adequate restraint and anchorage. Only minor damage incurred Optima is required to submit rack structural drawings and seismic analysis prior to release for fabrication

40. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 40 Rack Hazard Analysis EnergyHazardMitigation Electrical  Shock 480V  Arc Flash 0.2cal/cm^2  FPB=5 inches  Class 0 PPE, Class 00 gloves  Proper grounding  All welded construction  Metal straps between doors and frame  EEIP inspection at SLAC FireNoneAll non-flammable materials Gravity  3,000lbs  Review of rack design and fabrication drawings by seismic committee  Secure in accordance with seismic committee guidance Pressure Radiation Temperature NoneNot applicable

41. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 41

42. Paul Bellomo LCLS Racks bellomo@slac.stanford.edu March 30, 2006 42 Racks Status and Remaining Tasks Purchase order placed with Optima in February Rack design is acceptable - First Article released for fabrication Awaiting Optima seismic analysis Awaiting “First Article” delivery Delivery goal May 30, 2006 Assemble all systems into racks Test systems in racks prior to field installation

43. Paul Bellomo LCLS Cables bellomo@slac.stanford.edu March 30, 2006 43 DC Power Cables

44. Paul Bellomo LCLS Cables bellomo@slac.stanford.edu March 30, 2006 44 DC Cable and Conductor Sizing Per 2005 NEC Power SupplyRequired I= PS I /DeratingConductor Size 25V, 375A375A/(0.65*0.87) = 663A1/C500kcmil 700A 33V, 300A300A/(0.65*0.87) = 531A350kcmil 570A, use 1/C500kcmil 60V, 165A165A/(0.65*0.87) = 292A1/C2/0AWG 300A 200V, 50A50A/0.87 = 57A3/C#6AWG 75A 60V, 30A30A/0.87 = 34A3/C#10AWG 40A 40V, 12A12A/0.87 =13A3/C#12AWG 30A Basis – copper conductors, 90C insulation, max 45C ambient, 2005 NEC Tables 310-16 and 310-17 and cable tray fill per Article 392 for multi-conductor and single conductor cable, respectively. Flexible stranding, low smoke, zero halogen, suitable for cable tray use

45. Paul Bellomo LCLS Cables bellomo@slac.stanford.edu March 30, 2006 45 DC Cable Hazard Analysis EnergyHazardMitigation Electrical  Shock  Proper insulation voltage class  Jackets on cables pulled in cable trays  Isolate cables from public via raceways Fire  Overheating  Smoke  Size conductors for ampacity per NEC  Use fire retardant insulations and jackets  Low smoke, zero halogen construction GravityWeight of many cablesSupport systems meet seismic, NEC and NEMA VE-1 requirements PressureNoneNot applicable RadiationNoneNot applicable Temperature  Hot cables from excessive current and/or packing  Size conductors for ampacity per NEC to keep temperatures within insulation rating  Cable tray and raceway fill and isolation per NEC

46. Paul Bellomo LCLS Power Suppliesbellomo@slac.stanford.edu March 30, 2006 46 This is the Last Slide Test, Installation and Commissioning Plan Receive and bench test equipment – procedures exist Install in purchased racks in Building 24 Test as complete systems in B24 – need updated procedure Forklift entire rack assemblies from B24 to Sector 20 Install in Sector 20 Field test power systems – need updated procedure