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18-20 December 2006
3rd ATF2 Meeting, KEKATF2 Power Supplies 1
ATF2 High Availability DC Magnet Power Supplies
By Paul Bellomo, Antonio de Lira, David MacNair and Briant Lam*
18-20 December 2006
3rd ATF2 Meeting, KEKATF2 Power Supplies 2
Topics• Power System Overview
– Power Supply Requirements– Power Supply Controller– Power Supply Topology– Power System Diagrams
• Vendor Proposals• Awarded Vendor• Schedule• Responsibilities
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3rd ATF2 Meeting, KEKATF2 Power Supplies 3
Power Supply Requirements
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Power Supply Requirements• Generally, ATF2 Magnets require:
– up to 30 V– 50 to 200 A– Up to 10 ppm stability
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3rd ATF2 Meeting, KEKATF2 Power Supplies 5
Power Supply Controller• SLAC Ethernet Power Supply Controller
– Provides precision current regulation using a precision current transductor and an external analog current feedback loop
– 20-bit effective resolution for analog reference voltage (1 ppm accuracy measured)
– 2 ppm/ºC current stability– Continuous calibration– Interlocks for magnet protection– Analog readbacks
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3rd ATF2 Meeting, KEKATF2 Power Supplies 6
Power Supply Controller
22
12
21
22
2
function transfer loop closed 2 1
1
gain loopopen
CR
L R
RRπf
KKC
πf K
KsI
V
CRR
KK K
s
KG
R
LCR
O
O
OC
PSCT
CREF
CT
O
PSCT
O
O
• Control Loop– Classic PI
controller
– Size R2 and C2 for a critically damped system and bandwidth fc
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3rd ATF2 Meeting, KEKATF2 Power Supplies 7
Power Supply Controller
Front View
Rear View
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Power Supply Controller• Daughter Board
– Removable– Contains Magnet-
specific components• PI controller circuit• Burden resistors for
DCCT• EEprom to store IP
address and conversion constants
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3rd ATF2 Meeting, KEKATF2 Power Supplies 9
Power Supply Controller• Local Control Board
– Operate the power supply locally
– Access to diagnostic information
– A new Local Control Board is under development
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3rd ATF2 Meeting, KEKATF2 Power Supplies 10
Power Supply Controller• New Control Board
– Half the size– More robust– All the same controls
• Under Development– May be ready for
ATF2
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3rd ATF2 Meeting, KEKATF2 Power Supplies 11
Power Supply Topology• Power Module Blocks
– Use 30V, 50A blocks to construct power supplies– Simple Buck Regulator Topology– Add one extra power module for N+1 redundancy
to increase availability– High Availability is an absolute requirement for
success in the ILC
• Bulk Power Supply– Use off-the-shelf power supplies– Provide 40V regulated DC to Power Modules– One Bulk for several Power Supplies
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Power Supply Topology• Power Supply Specifications
– 30V, 50A Power Modules (Buck Regulators)– Common Crate for different configurations– Common Interface board to Controller– Analog and Digital readbacks/controls– N+1 redundancy– Automatic Current Sharing– Air-cooled rated for 50°C– Ground Current Detection
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Power System DiagramPower Supply
ControllerBy Purchaser
Power Supply
Power Supply
ControllerBy Purchaser
ControllerBy Purchaser
AC Input
Ethernet-EPICS I /O
Ethernet-EPICS I /O
Ethernet-EPICS I /O
Power Supply RackBy Purchaser
Magnet
Magnet
Magnet
Transductor
Current feedback
Bulk Power Supply
By Purchaser
Interlocks
Interlocks
Interlocks
Transductor
Redundantcurrent
readback
Transductor
Current feedback
Transductor
Redundantcurrent
readback
Transductor
Current feedback
Transductor
Redundantcurrent
readback
• One Bulk Power Supply per rack
• Multiple Power Supplies per bulk power supply
• One Controller per Power Supply
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3rd ATF2 Meeting, KEKATF2 Power Supplies 14
Rack Profile
Power System Diagram
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Power System Diagrams
Crate with 5 Modules Crate with 2 Modules
Status
I
O
Module 1 Module 2 Module 1 Module 2
Backplane
Output30V 50A
Output30V 50A
Controller
Interface:Clock, Phase Shifting, Fault
Reporting, Turn On Signal, Ground
Current, PS Voltage
Top View
Status
I
O
Status
I
O
Status
I
O
Front View
Input40V85AController
Interface:Clock, Phase Shifting, Fault
Reporting, Turn On Signal, Ground
Current, PS Voltage
DCCTGND I Sense
Common ModeOutput Filter
DCCTGND I Sense
Common ModeOutput Filter
Status
I
O
Module 1 Module 2 Module 3 Module 4 Module 5
Backplane
Output30V 200A
Input40V 170A
Controller
Interface BoardClock, Phase Shifting, Fault Reporting, Turn On Signal, Ground Current, PS
Voltage
Top View
Status
I
O
Status
I
O
Status
I
O
Status
I
O
Front View
DCCTGND I Sense
Common Mode Output Filter
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3rd ATF2 Meeting, KEKATF2 Power Supplies 16
Vendor Proposals• OCEM (Italy):
– Current mode control loop– Cost:
• IEPower (Canada):– Voltage mode control loop– Cost:
• Vektrex (USA)– DSP voltage control loop with 24-bit ADCs– Cost:
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3rd ATF2 Meeting, KEKATF2 Power Supplies 17
Awarded Vendor• OCEM
• Prices per power supply– Dual 50A:– 150A: – 200A:
• Prices per spare part– Power Module:– Crate (Single 100-200A):– Crate (Dual 50A):– (Crate includes interface board)
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3rd ATF2 Meeting, KEKATF2 Power Supplies 18
OCEM Proposal
Current Mode Controlled Buck Regulatorwith Slope Compensation
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OCEM Proposal
Power Suppliesused at Diamond
Power Supplies proposed for ATF2(from OCEM’s proposal)
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3rd ATF2 Meeting, KEKATF2 Power Supplies 20
OCEM Proposal
Power Module used in Diamond Power Supplies
Power Module proposed for ATF2(from OCEM’s proposal)
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OCEM Proposal
Interface board
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Vendor Schedule
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SLAC Schedule – Delivery
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Schedule - Commissioning
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Schedule• Immediate tasks:
– Purchase:• Bulk Power Supplies• Racks• PLC
– Drawings:• Electrical Interconnects within Racks• Rack Layout
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3rd ATF2 Meeting, KEKATF2 Power Supplies 26
Schedule• Information for KEK Tasks:
– DC Cable sizes:• 2 AWG for 50A Power Suppy (~40 mm2)• 4/0 AWG for all others (~140 mm2)• Cables are oversized to reduce cable loss and bulk
power supply size– AC Service
• 400 VAC, 3 Phase, 100A, 6 total• 100 VAC, 1 Phase, 20A, 9 total
• Items Needed from KEK:– ATF2 Commissioning Schedule
• Magnets; AC, DC, and control cables– Best time to commission Power Supplies
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3rd ATF2 Meeting, KEKATF2 Power Supplies 27
ResponsibilitiesPower supply system Responsibility
Controllers SLAC
Bulk Power Supplies SLAC
Power Supplies (Power Modules) SLAC
Cooling Fans SLAC
Racks SLAC
Intrarack cables SLAC
Controller Software SLAC
System Software KEK
Performance Test SLAC
Cables
Input AC cables KEK
DC cables to magnets KEK
DC cable raceway system KEK
Ethernet Cables to Controllers KEK
Magnet Interlock Cables to Controllers KEK
Installation
Wiring and Layout Diagrams SLAC
Training SLAC
Cable Termination SLAC
Testing System SLAC
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3rd ATF2 Meeting, KEKATF2 Power Supplies 28
Conclusion• Ethernet Power Supply Controller
• N+1 High Availability Power Supplies
• Awarded Vendor: OCEM
• Ready to deliver by: Dec 2007
• Ready to commission by: Feb 2008
• Responsibilities
• Comments or Questions?
