LCLSII 2 K Cold Box Controls Design Review

LCLS-II 2 K Cold Box Controls Design Review JLab 27 September 2016 2 K Cold Box Design Review 24 Aug 16 1 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Charge 7: Instrumentation & Controls • Is the electrical & controls design of the system sound? – Process control – Control system, devices/instruments – Electrical power 2 K Cold Box Design Review 24 Aug 16 2 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls Control System Overview Control System EPICS OPI EPICS Servers Cryo Controls Network Switch Panel. View 2 K Coldbox PLC Hardwired Stop, Cabinet Temp Vendor (x 5) Control Cabinet Motor Drive Mag Bearing Controller CANbus Gateway EPICS IOCs 2 K Coldbox Instrumentation (Sensors, Valves, etc. ) Motor Cold Compressor Power 120 V (UPS/Normal) Magnetic Bearings Temperature Sensor Speed Sensor Power (480 V/3 PH) 2 K Cold Box Design Review 24 Aug 16 3 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls: • Allen Bradley Control. Logix architecture as with all other SLAC Cryoplant systems • Dedicated PLC and touch screen for 2 K Coldbox • Redundant power feeds (UPS and Normal), 24 VDC, and PLC power supplies 2 K Cold Box Design Review 24 Aug 16 4 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls: • Cold compressors control loops same as JLAB – One primary PID loop for speed. All CC speed commands are dependent on this PID loop with a variable software gear ratio. – Follow a pre-established pump down sequence that varies gear ratios, which will be established at FDR. • Vacuum systems similar to 4 K CBX • Test heater controller (3 k. W) with integrated SCR controls and power measurement feedback 2 K Cold Box Design Review 24 Aug 16 5 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls CC Hardware/Safety Interface • Safety shutdown hardwired from PLC digital output directly to the motor drive – Allows to shutdown or inhibit drive from starting motor directly from PLC in the event the CANbus interface fails • Cabinet over-temperature – Fan controller fault to be wired to PLC – Allows to monitor if temperature rises 10 C above setpoint inside VFD cabinet • Local cabinet indicators – Error, Levitated, Rotating, Cabinet power ON 2 K Cold Box Design Review 24 Aug 16 6 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls CC Software interface • VFD Interface is CANbus and requires a Gateway to communicate to PLC. • Vendor provides CANbus communication. SLAC will procure a CANbus to Ethernet/IP gateway for direct communications to PLC hardware. • Vendor utilizes Siemens PLCs and SLAC uses Allen Bradley Control. Logix. • Program listing and additional information was requested and obtained from vendor to allow porting the Siemens interface program to Allen Bradley. 2 K Cold Box Design Review 24 Aug 16 7 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls CANbus Parameter List 2 K Cold Box Design Review 24 Aug 16 8 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls Electrical • Electrical wiring for cold compressor controls (Drive/AMB) have not yet been reviewed • Once reviewed, requested changes will be asked of vendor • Control cabinets to be located within 10 m from motors to accommodate maximum cable length 2 K Cold Box Design Review 24 Aug 16 9 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls Electrical • All motor controls will have the same power requirements • Temperature and pressure sensors will be standard JLab design • 4 K operation will utilize a bypass valve in the cold box 2 K Cold Box Design Review 24 Aug 16 10 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Instrumentation & Controls Identified risks • No access to VFD parameters Mitigation: – Vendor support during commissioning – Vendor to provide memory cards with combination of configurations to allow updates to VFD parameters • CANbus interface implementation Mitigation: – Procure spare VFDs ahead of schedule to allow time for development and testing of interface 2 K Cold Box Design Review 24 Aug 16 11 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Remaining Elec. & Cont. Work • Design of PLC enclosure, heater control enclosures, vacuum controls, instrument panels, and temperature layout and feedthroughs. 2 K Cold Box Design Review 24 Aug 16 12 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6

Summary • The LCLS-II 2 K CBX incorporated all the lessons learned in design, commissioning and operation over the last two decades on the three similar systems at JLab & SNS • The operational range is extended without exposing the project to higher risk • The design goal is to achieve the highest pressure stability and system efficiency 2 K Cold Box Design Review 24 Aug 16 13 JSA 2012 W 003, Mod 6 MSU RC 063215 -JSA-6