OVERVIEW OF SIRIUS POWER SUPPLIES
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1 OVERVIEW OF SIRIUS POWER SUPPLIES 6 th Power Converters for Particle Accelerators September 24 th 26 th 2018 LNLS/CNPEM Campinas - Brazil Gabriel Oehlmeyer Brunheira Power Electronics Group LNLS/CNPEM 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 1
2 OUTLINE Sirius project Power supplies families Digital controllers Production status 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 2
3 SIRIUS PROJECT Beam Energy 3.0 GeV SR Circumference m Lattice 20 x 5BA Hor. Emittance 0.25 nm.rad Nominal current (top up) 350 ma Booster cycling freq 2 Hz Beamlines (1 st budget) 13 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 3
4 SIRIUS PROJECT Building construction complete, infrastructure and finishing in progress 150 MeV LINAC from SSRF (turn-key) installed and commissioned Installation of booster vacuum chamber and magnets on going TL s and booster PS s start in mid October 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 4
5 POWER SUPPLIES FAMILIES Effort to standardize PS s from transport lines, booster and storage rings into only three families Ease development, production and maintenance Modular approach allows different combinations to fulfill all load specs Converters topology: Bipolar (correctors, trim coils and booster magnets): H-bridge + unipolar switching Unipolar (quadrupoles, sextupoles, dipoles): Buck + coupled inductors Associated modules interleaved (lower ripple and controller delay) PS Families FAC AC High Power FAP DC High Power FBP Low Power Module topology IGBT Buck + Capbank + IGBT H-Bridge Buck with Two- Interleaved IGBT MOSFET H-Bridge Module specs ± 550 A / 50 kw 300 A / 45 kw ± 10 A / 100 W Power Sirius kw kw W Total # of PS /09/2018 Overview of Sirius Power Supplies 6th POPCA 5
6 PS REQUIREMENTS LTB BTS Booster Magnets DIPOLES QUADRUPOLES STEERING MAGNETS DIPOLES QF QUADRUPOLES QF/QD STEERING HORIZONTAL MAGNETS VERTICAL DIPOLES QF QUADRUPOLES QD SF SEXTUPOLES SD STEERING MAGNETS SKEW QUADs Quadrant number Load inductance [mh] Load resistance [mω] Nominal current [A] Nominal voltage [V] Nominal output power [kw] PS model PS Quantity 1Q? FAP 1 4Q Q? FBP 11 1Q , FAP-4P 1 1Q FAP 1Q Q FBP 5 4Q Q FAC-2P4S 2 4Q FAC-2S 1 4Q Q ,710 FAC 1 4Q , Q Q? 256.3? 5? FBP 1 Storage Ring QUADRUPOLES (Main Coils) SEXTUPOLES QUADRUPOLES (Trim Coils) STEERING MAGNETS SKEW QUADs DIPOLES QFB (Q30) QFP (Q30) QFA (Q20) Q1, Q2,...(Q20) QDA, QDP1... QDB1, QDB2 SDB0, SDB1,... SDA0,.SDA1,... Q30 Q20 1Q FAP-2P2S 2 1Q Q Q Q FAP 1Q Q Q Q Q Q Q Q14 Horiz. 4Q Vertic. 4Q FBP 140 SLOW Vertic. 4Q Ext SLOW (Sext.) 4Q SLOW (Fast St.) 4Q TOTAL: /09/2018 Overview of Sirius Power Supplies 6th POPCA 6
7 FAC AC HIGH POWER PS Booster high-power cycling current sources Water-cooled IGBT s heatsinks and inductors 2 Hz triangular waveform 8 khz) DCCT Box (4U) Output stage (9U) Suppression of AC grid oscillation: Capbank voltage control: PI + notch 2 x n Hz Input current: PI + resonant 2 x n Hz Reference & capbank voltage feedforward to improve tracking error on load current Capbank (6U) Input stage (9U) Rectifier (6U) AC command (6U) 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 7
![BOOSTER QD/SD/SF PS S Nominal ratings Magnets L [mh] # PS 30 A / 40 V QD 135 1 150 A / 50 V SD 20 1 150 A](/docs-images/88/117913674/images/8-0.jpg "/ 70 V SF 50 1 T: 50 ms/div CH1: Load voltage (20 V/div) CH3: Capbank voltage (1 V/div) CH3: Load current")
8 BOOSTER QD/SD/SF PS S Nominal ratings Magnets L [mh] # PS 30 A / 40 V QD A / 50 V SD A / 70 V SF 50 1 T: 50 ms/div CH1: Load voltage (20 V/div) CH3: Capbank voltage (1 V/div) CH3: Load current (30 A/div) CH4: AC Input current (5 A/div) 11 A Peak load current: 150 A Load: 39 mh / Ω Capbank: 80 V DC / 8 V pk-pk DC-Link current limitation: 28 A 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 8
![L [mh] # PS FAC-2S 120 A / 500 V](/docs-images/88/117913674/images/9-3.jpg "QF 540 1 FAC-2P4S 1100 A / 800 V")
9 BOOSTER QF AND DIPOLES PS S PS Topology Nominal ratings Magnets L [mh] # PS FAC-2S 120 A / 500 V QF FAC-2P4S 1100 A / 800 V Dipoles /09/2018 Overview of Sirius Power Supplies 6th POPCA 9
10 FAC AC HIGH POWER PS Peak load current: 380 A Load: 11.5 mh / Ω Capbank: 195 V DC / 8.6 V pk-pk Buck input current: 40.1 A DC / 5.6 A pk-pk T: 200 ms/div CH1: Capbank voltage (5 V/div) CH3: Load current (112.5 A/div) CH4: Input current (5 A/div) MATH: CH4 FFT (20 db/div) Notch filters and ressonant controllers on 2 Hz and 4 Hz 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 10
11 FAP DC HIGH POWER PS Transport lines and storage ring high-power converters Buck converter with 2 interleaved IGBTs connected by coupled inductors (developed in-house). Water-cooled heatsink and inductors. Manifold installed inside racks to distribute between different power modules 98% eff typ. IGBT s temp: 49ºC Inductors temp: 68ºC Off-the-shelf adjustable DC-links optimize output stage to work at 50% duty-cycle High voltage: Regatron TopCon Low voltage: TDK Lambda HFE 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 11
12 FAP DC HIGH POWER PS BTS Quadrupoles PS s 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 12
13 FAP DC HIGH POWER PS LTB/BTS Dipoles and Quad s Storage Ring Dipoles and Quad s Storage Ring Sextupoles 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 13
14 FBP LOW POWER PS Storage Ring Booster LTB BTS Quad Trim Coils Corrector Magnets Skew Quad Corrector Magnets Skew Quad Quad Corrector Magnets Corrector Magnets U crate houses up to 4 individual ±10 A / ±10 V Air-cooled forced by rack exhaustor (except TL) > 4 khz bandwidth MOSFETs H-Bridge (f PWM = 50 khz) + 2nd order LCdamped filter - 89% eff typ. Off-the-shelf AC/DC converters for shared DC-link among crates from same rack (adjustable for different set of loads) First prototypes installed at UVX s LINAC two years ago and 10 units of final version installed this year. FBP rack for TL s already in place at Sirius 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 14
15 FBP LOW POWER PS LTB/BTS FBP power supplies DC-Link for quadrupoles DC-Link for correctors Load current (~ 5A) 38.1 ua (19 bits) T: 200 us/div CH1: load current (200 ma/div) 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 15
16 DRS DIGITAL CONTROLLER 3U based in-house development, with initial partnership with University of Campinas UDC (Universal Digital Controller): Dual-core TI F28M36P63C2: ARM + DSP Up to 4 indepen. PI 100 khz HRADC (High-Resolution A/D Converter): 18 up to 600 ksps Voltage / current input (Vishay VPR burden) UDC HRADC 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 16
17 DRS ECOSYSTEM POF Sync In/Out UDCNet CAN 16x POF PWM Interlock board (CAN with UDC) Auxiliary board (AC contactor/relays, isolations, etc) Expansion board with isolated AIN + DI/O s from/to multiple PS power stages 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 17
18 DRS FAX CONTROLLERS Booster Dipole Controller LTB/BTS 16x PS Controllers POF PWM Cascaded RS /09/2018 Overview of Sirius Power Supplies 6th POPCA 18
19 HIGH-LEVEL INTERFACE Current PS, Pulsed, RF,... EPICS plataform (pydm, CCS,...) Power supplies IOC s implemented on SBC modules based on BeagleBone Black: 6Mbps BSMP protocol (in-house) Synchronization by serial interface, instead on direct pulses 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 19
20 FAC FAP FBP PRODUCTION & TESTS 100% modules manufactured, ~90% tested Racks integration and tests in progress 100% modules manufactured All LTB/BTS modules tested, racks integration finish on next fews days 1 rack (LTB/BTS) installed and operating with dummy loads 380 power supplies (95 crates) delivered and tested sufficient for Sirius operation without trim coils and QS DCCTs recall (~50%!!) DRS (FAC/FAP) > 90% electronics completed (in-house HW customization) LTB, BTS and Booster PS controllers assembled, under tests Cabling and rack integration on going Firmware in progress 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 20
21 PRODUCTION & TESTS 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 21
22 PRODUCTION & TESTS 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 22
23 THANK YOU! 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 23
24 One project/core to maintain (Git) New PS models require only 2 files: new_model.c (source) new_model.h (header) Completely parameterized PWM settings (freq/dead-time/sat) Communication settings Control parameters Interlocks thresholds # PS (FBP only)... Control laws are built and run blockwise inside each PS module 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 24
25 BOOSTER DIPOLE INPUT CONTROL 25/09/2018 Overview of Sirius Power Supplies 6th POPCA 25
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