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SPS NORTH and PS EAST AREAS POWER CONVERTERS

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

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SPS NORTH and PS EAST AREAS POWER CONVERTERS

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  1. 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

  2. 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

  3. 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

  4. SPS NORTH AREA POWER CONVERTERS • In operation since 1976 • Original analog & digital electronics • Wire wrap technology ATC-ABOC Days 24/01/07

  5. SPS NORTH AREA POWER CONVERTERS Cables Plats Ethernet Old control system 2x40 Ethernet 2x40 2x40 PCA PCA CAMAC 1553 MODULES TG3 JCPP GPS BA8x IOR 1420 IOR 1420 IOR 1420 NASB8x I G CRATE O R VCC Com 1 1x50 1x50 1x50 Patch Panel SK31/2 SK31/3 SK31/1 SK3B SK3A SK8 To CAMAC SK2 Timing Cde DELESTAGE SK 5 FTM Coax. SK4/5/6 SK20 JUNCTION CRATE P0 SURVEY Coax. SK6 FTE PUPITRE CRN CRN Coax. SK7 Start Pulse SK10 SK11 SK2 SK3 B8 SK3/1-2 Access Norh Area Compensateur BE Heures Critiques BE 1x100 DATA BUS SK3 SK3 DUMP CONTROL CONVERTER CRATE CONVERTER CRATE LOGIC SK200 SK300 SK200 SK300 TAX 7 POWER SUPPLY CRATE POWER SUPPLY CRATE TAX 12 ATC-ABOC Days 24/01/07

  6. SPS NORTH AREA POWER CONVERTERS • CAMAC + PCA • Junction Crate : Digital Electronic uP 6809, Flex based system ATC-ABOC Days 24/01/07

  7. TIMING SPS ETHERNET CONSOLE CONSOLE SK20 VME CRATE DELESTAGE BE SAC ICV 196 BA80: V2NB80 RIO8062 + CTRP BA81: V2NB81 P0 SURVEY SK3 BA82: V2NB82 1x100 DATA BUS SK3 SK3 DUMP CONTROL CONVERTER CRATE CONVERTER CRATE LOGIC SK200 SK300 SK300 SK200 TAX 7 POWER SUPPLY CRATE POWER SUPPLY CRATE TAX 12 SPS NORTH AREA POWER CONVERTERS New control system ATC-ABOC Days 24/01/07

  8. SPS NORTH AREA POWER CONVERTERS SOFTWARE ARCHITECTURE VME CRATE CESAR AB/CO/AP FESA AB/CO/FE OPERATION POW SPECTRO LASER ALARMS AB/CO/AP CMW CMW POWJC AB/CO/IN AB/PO/CC SPECIALISTS APPLICATIONS AB/PO/CC SPECTROMETERS MAGNETS MAGNETS ATC-ABOC Days 24/01/07

  9. 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 bus Ready for next run. ATC-ABOC Days 24/01/07

  10. SPS NORTH AREA POWER CONVERTERS FAULTS STATISTICS ATC-ABOC Days 24/01/07

  11. SPS NORTH AREA POWER CONVERTERS Electronic card reliability MAIN CONCERNS PCB connector contact ~ 6600 electronic modules of this type are in operation Wire wrap Obsolete components Cabling ageing Split insulation Damaged gilded contacts ATC-ABOC Days 24/01/07

  12. 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

  13. 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

  14. 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

  15. 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

  16. 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/R2G 1000A / 220V • R2B 1000A / 250V • R31 2500A / 355V • R6 2500A / 500V 5000A / 1000V • 1 voltage booster type: • D0 1000A / 150V ATC-ABOC Days 24/01/07

  17. PS EAST AREA POWER CONVERTERS • In operation since 1970 • Electronics replacement in 1991 • PS standard control (1553) ATC-ABOC Days 24/01/07

  18. PS EAST AREA POWER CONVERTERS FAULT STATISTICS ATC-ABOC Days 24/01/07

  19. 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 sensors Studies 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

  20. SPS NORTH and PS EAST AREAS POWER CONVERTERS CONCLUSION SPS 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 ATC-ABOC Days 24/01/07

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