Power Supply Status

1 BROOKHAVEN SCIENCE ASSOCIATES

Power Supply Status

George GanetisPower Supply Status

ASAC Review October 22-23, 2009


Outline

• Storage Ring Overview • Short Term Goals• Multipole PS• Corrector PS• PS Controller• DCCT & DVM Calibration• Transport Line & Booster PS• Look Ahead – Short & Long Term• Conclusions


Overview – Storage Ring Power SuppliesThis summary table includes approved and pending controlled changes

Power Supply-Model

Qty Max. Voltage

Max Current

Configuration Stability /Resolutionppm of max I

Operation

Main Dipole 1 1200 V 450 A Unipolar Switch-Mode , Digital Regulatorcenter point tied to GND

25 3.8

DC 1 Quadrant

Large ApertureTrim

1 300 V 13 A Unipolar Switch-ModeAnalog Curr. Regulator

10015

DC1 Quadrant

Quadrupole -A -B -C -D

601206060

16 V22 V30 V30 V

175 A175 A175 A215 A

Unipolar Switch-ModeAnalog Curr. Regulator1 PS per Magnet

503.8

DC1 Quadrant

Sextupole -A -B -C -D

355512

40 V60 V80 V16 V

120 A165 A120 A120 A

Unipolar Switch-ModeAnalog Curr. RegulatorModel A & B = 1 PS per 6 MagnetsModel C = 1 PS per 12 MagnetsModel D = 1 PS per 2 Magnets

10015

DC1 Quadrant

Global Horz. & Vert.Correctors -A

90 12 V 1.25 A 2 Channel Bipolar Linear Analog Curr. Regulator

10015

10000 Hz4 Quadrant

Insertion Horz. Correctors -B

12 30 V 30 A Unipolar Switch-ModeAnalog Curr. Regulator

503.8

DC1 Quadrant

Skew Quad Corrector-C

30 20 A 20 A Bipolar LinearAnalog Curr. Regulator

10015

DC4 Quadrant

Alignment Horz. & Vert. Correctors -D

180 25 V 22A 2 Channel Bipolar Linear / Pre-RegulatorAnalog Curr. Regulator

253.8

3 Hz2 Quadrant

Dipole Trim –Corrector -E

27 20 V 5 A 2 Channel Bipolar Linear / Pre-RegulatorAnalog Curr. Regulator

10015

DC4 Quadrant

Dipole Trim –Corrector -F


10015

DC4 Quadrant


Short Term Goals

• Main Dipole PS• Engineering analysis for switch-mode topology• Assemble & test prototype digital current regulator• Test series pass filter• Start final design

• Multipole PS• Build & test prototype major system components - current regulator , ps interface, ps controller, & AC control

module.• Test ps components for a complete ps in the nominal rack configuration.• Assemble multiple ps in rack for long term testing and software development.• Start final design of major system components.

• Corrector PS• Build & test prototype major system components - current regulator , ps interface, ps controller, & AC control

module.• Build & Test Power Amplifiers for Type A & D models ( New 2 channel designs )• Test ps components for a complete ps in the nominal rack configuration.• Assemble multiple ps in rack for long term testing and software development.• Start final design of some major system components.


Main Dipole Power Supply

• Decision was made to use a switch mode topology for the power converter section.

• Detailed circuit models for the power converter, filter, and series pass have been made and we are in the process of analyzing results.

• Procurement specifications will start soon.

• Detailed design on digital current regulator has started


Main Dipole Power SupplyCurrent Regulator Controls Prototype

Test setup is build for digitalcurrent regulator.Software work on the prototype regulator was just started this summer.

Switch mode PSLow voltage

DCCTElectronics

DSPElectronics

Series Pass Filter

DCCTHead

ResistiveLoad

Preliminary results of current output stability = + 1 ppm

DVM

ADC


Multipole Power Supplies

This configuration used for Quadrupole & Sextupole magnet circuits.

Standard commercial power converter are being used.

Three prototypes ps have been constructed and are under test.

These ps are installed in the temperature controlled racks.

Systems are under test using thecurrent regulator and power supply interface.

Instrumentation ( DVM/Scanner & 1-wire sensors ) are being used in testing.

PS Controller is in detailed design


Current Regulator Card

Prototype low noise current regulator.

Two built by hand, 8 more have been assembled at a vendor by machine.

Electronic adjustment of offset & gain of critical circuits.

Diagnostic signals brought out to both slow high precision DVM and fast ADC on PSI.

Preliminary tests show < 5ppm current stability for 1 hour.

1

1

1 2

35

1= Switch mode low level power supplies2= Low noise power conditioning filters3= Micro-controller used for state control & interlocks4= Precision burden resistors to convert current from DCCT to voltage5= High gain low noise analog current regulator

4


Power Supply Interface Card

1= Switch mode low level power supplies2= Low noise power conditioning filters3= FPGA used to convert fiber optic data to DACs & ADCs4= Micro-controller used for temperature Control of DACs5= Temperature stabilized DAC daughter board6= Analog signal connector to Current Regulator Card

1

2

34

5

Ten prototypes built by vender assembled by machine.PS Current Setpoint-Two 18 bit DACsDiagnostic signals-Nine 16 Bit ADC – -3 High Precision ADC-6 Low Precision ADCState Control & Status-8 Digital Outputs-16 Digital InputsFiber Optic Data Transfer to PSC is 10 kHz.Slow Serial Port Preliminary tests show < 5ppm DAC stability for 1 hour.

6


Power Supplies Rack Tests

Sextupole

Quadrupole

Quadrupole

Corrector

Corrector

AC Input Module

DCCTs

Regulator

Pwr Converter

Cold Air Blower

TemperatureControlled

Rack

Power supply test are done in temperature controlled racks that are close to the final design that will be installed in the machine.

Test with multiple power supplies - Will be looking for electrical noise interactions and thermal issues.

Rack configuration was reviewed by BNL fire safety personal and found no issues with the design or materials selection.


Test of Complete Multipole PSThis is both Current Regulator & PSI

Initial Results


Test of Complete Multipole PSThis is both Current Regulator & PSI

Initial Results


Corrector Power Supplies

Separated function corrector scheme will replace the combined function correctors.

There will be 6 slow alignment & 3 fast small corrector magnets per cell.

The new scheme added 180 new magnet circuits for the fast small correctors.

To cover the cost of the new circuits, we developed a new ps configuration – a 2 channel ps.The design shares some main components to reduce

costs.

It required the addition of components in the regulator and psi to make it a 2 channel version.

Engineering studies has determined that the extra components will fit into the exiting form factors

The power converter and amplifier are being re-designed to fit in ½ the nominal space. ( Less rack space )

(Highlighted)


Corrector Power Supplies

The new fast small corrector requires a much smaller AC bend strength then the baseline design. 80 urad vs 10 urad at 10 Hz.

The reduced size of the magnet also required less amp-turns for the 10 urad bend strength.

1 amp coil design was chosen to minimize the cost of the power supply system. This allowed the use of precision shunts to be used instead of more costly DCCTs.

The stability requirements were relaxed compared to the alignment correctors. ( Less Cost )

This design will use the same the same regulator and psi as in the alignment correctors. ( 2 Cha. )

The low current of this ps and the use of shunts as the feedback element will also allow a higher bandwidth then what could have been achieved with DCCTs.


Controls System Interface

Controls Group Responsibility

PS Group Responsibility

Very close working relations with Controls Group

Clear hardware interface boundaries.

Good software support to date.


Power Supply Controller

1st Rear Board

50Ω

50Ω

Rea

r b

oar

d c

on

ne

cto

rRJ45

RJ45IC SPARTAN-3A

FPGA

XC3S1400A-5FGG676C

1st Front Board

50Ω2222

LocalDC/DC

converters

100MHz PLLTx

Rx

2

3

Read readyWrite data

Write ready5

141 F

ron

t bo

ard co

nn

ecto

r

JTAG

Read data

FPGA programmingB

ackp

lan

e w

ith

fee

d t

hro

ug

h c

on

nec

tor

LocalDC/DC

converters

InterfaceRx

Tx

J8064D628ANL10/100 Base-TX To SDI

Optical Fibersto PSI

Address/Command

4

1R/W* Command

50Ω50Ω50Ω

CY7C68013AUSB FX2

USB2

Timing/Event Interface (Bussed) 16

128Mx8, 256MBx8 or 512Mx8

DDR2 Memory

MT47HxxxM8 60-63 BGA

128Mx8, 256MBx8 or 512Mx8

DDR2 Memory

MT47HxxxM8 60-63 BGA

KSZ8851

KSZ8851 Magnetic

MagneticLED 01,02

LED 03,04

LED 05,06

LED 07,08

LED 09,10

LED 11,12

LED 13,14

LED 15,16

RJ45 Magnetic 50Ω50Ω

Active Terminations

Slots 1 & 21 only

Permit Interface (Daisy chained) 4Pull-

Down

PSC Chassis can hold up to 20 main & transition cards

One main card can control a single or dual channel PSI

FPGA has DSP capabilities for waveform generation & diagnostic functions analysis.

The main cards have large on board memory for waveform & diagnostic storage.

Transition boards have SDI & fiber optic connections


DCCT & DVM Calibration

National Standards

Portable 10 V

Standard

Portable 10 V

Standard

BNL DCCT Bridge

In-Situ Cal.

24 hour

90 day

180 day

1 year

V 0.5 2.5 4

Ω 1 5 8

BNL Primary Standards

DCV Transfer

Traveling DCCT

Standard

In-Situ Cal.

In PPM

We will test ~ 1800 DCCT before installation.

DVM

PS Rack


Transport Line PS

• Transport line power supplies will use same hardware as the storage line. Current Regulator, PSI, PSC, DVM/Scanner, 1-Wire devices, & Commercial Power Converters.

Power Supply-Model

Qty Max. Voltage

Max Current

Configuration Stability /Resolutionppm of max I

Operation

LBTL Dipole –A -B

1 1

75 V40 V

200 A125 A

Unipolar Switch-Mode Analog Curr. Regulator1 PS per Magnet

10015

DC 1 Quadrant

LBTL Quadrupole -A -B

12 6

16 V50 V

175 A175 A


10015

DC1 Quadrant

LBTL Alignment Horz. & Vert. Correctors

8 20V 20A 2 Channel Bipolar Linear / Pre-RegulatorAnalog Curr. Regulator

10015

3 Hz2 Quadrant

BSRTL Dipole 5 75 V 200 A Unipolar Switch-Mode Analog Curr. Regulator1 PS per Magnet

100 15

DC 1 Quadrant

BSRTL Quadrupole -A -B

14 4

30 V16 V

175 A175 A


10015

DC1 Quadrant

BSRTL Alignment Horz. & Vert. Correctors


10015

3 Hz2 Quadrant


Booster PS Controls

PSI # 1Dual Channel

PSI # 2Single Channel

PSI # K

PSCPower Supply Controller # 1

PSC Master- - - - - - - - - -

SDI

PSCPower Supply Controller # 2

PSCPower Supply Controller # M

Booster PS # 1

Booster PS # X

Booster PS # 2

Booster PS # 3

Fiber Optic Link 50Mbit/s

SDI protocol100Mbit

Booster Power Supply Control

SDI - LOOP

IOCVME Chassis

WithTiming Event

Reciever

Standard Ethernet

BoosterPower Supply

TimingSignals

• Booster power supplies will use BNL supplied controls PSI,PSC, & IOC

• Vendor will supply current regulator and state control & interlocks


Look Ahead – Short Term ( next 6 months )

• Continue testing single channel power supply interface ( PSI )• Finish design, build & test power supply controller ( PSC )• Design , build, & test two channel current regulator and two channel psi• Finish design , build, and test corrector D power amplifier ( Alignment

Corrector )• Design, build, & test corrector A power supply ( Fast Global Corrector )• Continue on software development for controls and instrumentation• Continue long term testing of power supplies and components.


Look Ahead – Long Term

Storage Ring Power Supply Schedule


Conclusions

• Good progress is being made in the main dipole ps with the addition of the new engineer.

• Multipole power supplies are in good shape, working prototype supply will easily meets requirements.

• We are a little behind in corrector work due to the re-direction of the requirements. We should be able to recover in the next 6 months with the prototypes being built.

• We have a rack system setup for long term testing and software development.

• Detailed procurement plans have been developed. We are actively working with vendors and NSLS II Procurement in developing manufacturing plans and specifications. We are using prototype builds to qualify vendors.

Documents

Power Supply Status