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SPS NORTH and PS EAST AREAS POWER CONVERTERS. Situation of the power converters of the SPS and PS experimental areas Y.Gaillard AB/PO. SPS NORTH and PS EAST AREAS POWER CONVERTERS. CONTENTS SPS NORTH AREA Equipments presentation New control system Start-up problems - PowerPoint PPT Presentation
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ATC-ABOC Days 24/01/07
SPS NORTH and PS EAST AREAS POWER
CONVERTERS
Situation of the power converters of the SPS and PS experimental
areas
Y.Gaillard AB/PO
ATC-ABOC Days 24/01/07
SPS NORTH and PS EAST AREAS POWER
CONVERTERS
CONTENTS SPS NORTH AREA
• Equipments presentation
• New control system
• Start-up problems
• Operation in the coming years
PS EAST AREA• Equipments presentation
• Main concerns
CONCLUSION
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
330 PC (25kW 3.6MW)
3 buildings: BA80, BA81, BA82
8 power converter types:• C11 250A / 100V
• R11 500A / 150V
• R12 500A / 300V
• R13 500A / 225V
• R21 1000A / 300V
• R22 1500A / 250V
• R31 2500A / 255V
• R41 6000A / 600V
2 voltage booster types:• D21 1500A / 200V
• D31 2500A / 285V
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
In operation since 1976 Original analog & digital electronics Wire wrap technology
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
CONVERTER CRATE CONVERTER CRATE
POWER SUPPLY CRATE POWER SUPPLY CRATE
JUNCTION CRATE
DATA BUS
PCA
Com 1SK
8
JCPP
DELESTAGE
PUPITRE CRN
SK3/1-2
SK20
SK31
/1
SK31
/2
SK31
/3
IOR
142
0
IOR
142
0
IOR
142
0 CAMAC
CRATE
P0 SURVEY CRN
DUMP CONTROL
TAX 7
TAX 12
O R
VCC
Cables Plats
SK5 FTM
SK6 FTE
SK7 Start Pulse
SK2 Timing Cde
Ethernet
MODULES TG3PCA
GPS BA8xNASB8x
1553
LOGIC
SK200 SK200SK300 SK300
SK3 SK3
Ethernet
1x50
1x50
1x50
2x402x402x40
1x100
Coax.
Coax.
Coax.
I G
SK3 B8
To CAMAC
Patch Panel
SK4/5/6
SK3A
SK3B
SK10Access Norh Area
SK2
Compensateur BE
SK11
Heures Critiques BE
Old control system
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
Junction Crate : Digital ElectronicuP 6809, Flex based system
CAMAC + PCA
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
New control system
ICV
196
RIO
8062
+ C
TRP
SAC
CONVERTER CRATE CONVERTER CRATE
POWER SUPPLY CRATE POWER SUPPLY CRATE
DATA BUS
DUMP CONTROL
TAX 7
TAX 12
LOGIC
SK200 SK200SK300 SK300
SK3 SK3
1x100
VME CRATE DELESTAGESK20
SK3
BA80: V2NB80BA81: V2NB81BA82: V2NB82
BE
TIMING SPS
ETHERNET
CONSOLE
CONSOLE
P0 SURVEY
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
SOFTWARE ARCHITECTURE
CESAR AB/CO/AP
LASER ALARMS AB/CO/AP
SPECIALISTSAPPLICATIONS AB/PO/CC
FESA AB/CO/FE
POWJCCMW CMW
AB/CO/IN
MAGNETS
VME CRATE
OPERATION POWSPECTRO
SPECTROMETERS MAGNETS
AB/PO/CC
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
START UP PROBLEMS
DATABUS timing synchronization problem• Problem: The address trigger signal came too early
• Consequence: Several converters were commanded simultaneous
• Solution: The address signal was slowed down in POWJC
DATABUS current load• Problem: To many cards connected to ICV196
• Consequence: Some commands were unsuccessful
• Temporary solution: P42-K12 converters disconnected
• Final solution: Drivers will be installed to control the data busReady for next run.
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
FAULTS STATISTICS
2004 2006
Exploitation period 26 weeks 20 weeks
Interventions 166 162
Duration of interventions 130 H 155 H
Mean intervention time 47’ 57’
Interventions / converters ratio 0.4 0.52
Power faults 21 12
Electronics faults 94 91
Operation faults 6 29
External faults 18 30
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
MAIN CONCERNSElectronic card reliability
PCB connector contact
Cabling ageing
Wire wrap Obsolete
components
Split insulationDamaged gilded contacts
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
100 electronic cards have to be repaired each year
The MTBF of the power converter is very low: ~7000H
Each fault is limited to a beam line (over 6 in north area)
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
OBJECTIVES FOR THE COMING YEARS
Keep the same maintenance level with special actions Change obsolete IC of the address cards Clean connectors of the address cards
Keep the same operation expertise First Line training
Keep the intervention time of 1 hour
Improvements can only come with a consolidation program
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
FUTURE CONSOLIDATION PROJECT
Replace 180 power converters (≤500A) by new switch-mode power converters.
Renovate 150 thyristor converters.
New electronic control.
ATC-ABOC Days 24/01/07
SPS NORTH AREA POWER CONVERTERS
ESTIMATION
Budget estimation : 23 MCHF
Provisional schedule: 6 years
• 2 years studies and contracts
• 4 shutdowns for implementation
Manpower: 19 FTE
No budget allocated in AB consolidation! (below red line!)Nothing before 2010!
ATC-ABOC Days 24/01/07
PS EAST AREA POWER CONVERTERS
80 PC (8kW 2.5MW)
2 buildings: 251, 263
10 power converters types:• T1B 250A / 32V
• R10 250A / 50V
• R1 500A / 100V
• R3 800A / 300V
• R2 950A / 200V
• R2A/R2G1000A / 220V
• R2B 1000A / 250V
• R31 2500A / 355V
• R6 2500A / 500V5000A / 1000V
1 voltage booster type:• D0 1000A / 150V
ATC-ABOC Days 24/01/07
PS EAST AREA POWER CONVERTERS
In operation since 1970 Electronics replacement in 1991 PS standard control (1553)
ATC-ABOC Days 24/01/07
PS EAST AREA POWER CONVERTERS
2004 2006
Exploitation period 28 weeks 22 weeks
Interventions 40 41
Duration of interventions 33 H 53 H
Mean intervention time 37’ 76’
Interventions / converters ratio 0.61 0.63
Power faults 9 8
Electronics faults 14 8
Operation faults 2 8
External faults 15 17
FAULT STATISTICS
ATC-ABOC Days 24/01/07
PS EAST AREA POWER CONVERTERS
MAIN CONCERNS
Polarity switches :• Blocked with 0A reference
A software modification will be done for next run
• Some problems with old mechanical position sensorsStudies to install optical sensors are in progress
Auxiliary power supplies VERO :• Trivolts VERO are not reliable
Studies to install power modules + DC/DC converters are in progress
ATC-ABOC Days 24/01/07
SPS NORTH and PS EAST AREAS POWER
CONVERTERS
CONCLUSIONSPS North area The new control system is operational since April 2006 It became stable in September after POWJC corrections Electronic reliability is the main concern Improvements can only come with a consolidation program Project could start in 2010 if a budget is allocated
PS Earth area Old power converters No consolidation program Can we improve diagnostic for magnet faults ? Call the right
service! What is the future of EAST areas with PS2?
Both Areas are using old power converters with not reliable electronics
=> High number of First Line interventions