SPS NORTH and PS EAST AREAS POWER CONVERTERS

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SPS NORTH and PS EAST AREAS POWER CONVERTERS Situation of the power converters of

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 u SPS NORTH AREA •

SPS NORTH and PS EAST AREAS POWER CONVERTERS CONTENTS u SPS NORTH AREA • • u Equipments presentation New control system Start-up problems Operation in the coming years PS EAST AREA • Equipments presentation • Main concerns u CONCLUSION ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS u 330 PC (25 k. W 3. 6 MW)

SPS NORTH AREA POWER CONVERTERS u 330 PC (25 k. W 3. 6 MW) u 3 buildings: BA 80, BA 81, BA 82 u 8 power converter types: • • u C 11 R 12 R 13 R 21 R 22 R 31 R 41 250 A / 100 V 500 A / 150 V 500 A / 300 V 500 A / 225 V 1000 A / 300 V 1500 A / 250 V 2500 A / 255 V 6000 A / 600 V 2 voltage booster types: • D 21 • D 31 1500 A / 200 V 2500 A / 285 V ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS u u u In operation since 1976 Original analog

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

SPS NORTH AREA POWER CONVERTERS Cables Plats Ethernet 2 x 40 I G OR

SPS NORTH AREA POWER CONVERTERS Cables Plats Ethernet 2 x 40 I G OR VCC CRATE MODULES TG 3 SK 4/5/6 SK 20 JUNCTION CRATE PUPITRE CRN SK 11 SK 2 To CAMAC SK 5 FTM Coax. SK 6 FTE Coax. P 0 SURVEY CRN SK 7 Start Pulse. Coax. SK 10 Access Norh Area Compensateur BE Heures Critiques BE PCA GPS BA 8 x Patch Panel SK 2 Timing Cde DELESTAGE 1553 1 x 50 IOR 1420 CAMAC SK 31/3 1 x 50 SK 31/1 SK 8 SK 3 B SK 3 A Com 1 SK 31/2 NASB 8 x 1 x 50 JCPP IOR 1420 PCA Ethernet SK 3 B 8 SK 3/1 -2 1 x 100 DATA BUS SK 3 CONVERTER CRATE DUMP CONTROL CONVERTER CRATE LOGIC Old control system SK 200 SK 300 POWER SUPPLY CRATE TAX 7 TAX 12 ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS u Junction Crate : Digital Electronic u. P 6809,

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

SPS NORTH AREA POWER CONVERTERS TIMING SPS ETHERNET CONSOLE ICV 196 RIO 8062 +

SPS NORTH AREA POWER CONVERTERS TIMING SPS ETHERNET CONSOLE ICV 196 RIO 8062 + CTRP SAC CONSOLE VMECRATE BA 80: V 2 NB 80 BA 81: V 2 NB 81 BA 82: V 2 NB 82 SK 20 SK 3 BE DELESTAGE P 0 SURVEY 1 x 100 DATA BUS SK 3 CONVERTER CRATE SK 200 SK 300 POWER SUPPLY CRATE DUMP CONTROL CONVERTER CRATE SK 200 LOGIC SK 300 POWER SUPPLY CRATE TAX 7 TAX 12 ATC-ABOC Days 24/01/07 New control system

SPS NORTH AREA POWER CONVERTERS SOFTWARE ARCHITECTURE VME CRATE CESAR AB/CO/AP FESA OPERATION AB/CO/FE

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

SPS NORTH AREA POWER CONVERTERS START UP PROBLEMS u DATABUS timing synchronization problem •

SPS NORTH AREA POWER CONVERTERS START UP PROBLEMS u DATABUS timing synchronization problem • Problem: • Consequence: • Solution: u The address trigger signal came too early Several converters were commanded simultaneous The address signal was slowed down in POWJC DATABUS current load • • Problem: To many cards connected to ICV 196 Consequence: Some commands were unsuccessful Temporary solution: P 42 -K 12 converters disconnected Final solution: Drivers will be installed to control the data bus Ready for next run. ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS FAULTS STATISTICS 2004 2006 Exploitation period 26 weeks 20

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 CONCERNS Electronic card reliability PCB connector contact Wire

SPS NORTH AREA POWER CONVERTERS MAIN CONCERNS Electronic card reliability PCB connector contact Wire wrap Obsolete components Cabling ageing Damaged gilded contacts Split insulation ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS u 100 electronic cards have to be repaired each

SPS NORTH AREA POWER CONVERTERS u 100 electronic cards have to be repaired each year u The MTBF of the power converter is very low: ~7000 H u 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 u Keep the same

SPS NORTH AREA POWER CONVERTERS OBJECTIVES FOR THE COMING YEARS u Keep the same maintenance level with special actions [ [ u Change obsolete IC of the address cards Clean connectors of the address cards Keep the same operation expertise [ First Line training u Keep the intervention time of 1 hour u Improvements can only come with a consolidation program ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS FUTURE CONSOLIDATION PROJECT u Replace 180 power converters (≤

SPS NORTH AREA POWER CONVERTERS FUTURE CONSOLIDATION PROJECT u Replace 180 power converters (≤ 500 A) by new switch-mode power converters. u Renovate 150 thyristor converters. u New electronic control. ATC-ABOC Days 24/01/07

SPS NORTH AREA POWER CONVERTERS ESTIMATION u u Budget estimation : 23 MCHF Provisional

SPS NORTH AREA POWER CONVERTERS ESTIMATION u u 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 u 80 PC (8 k. W 2. 5 MW)

PS EAST AREA POWER CONVERTERS u 80 PC (8 k. W 2. 5 MW) u 2 buildings: 251, 263 u 10 power converters types: • T 1 B 250 A / 32 V • R 10 250 A / 50 V • R 1 500 A / 100 V • R 3 800 A / 300 V • R 2 950 A / 200 V • R 2 A/R 2 G 1000 A / 220 V • R 2 B 1000 A / 250 V • R 31 2500 A / 355 V • R 6 2500 A / 500 V 5000 A / 1000 V u 1 voltage booster type: • D 0 1000 A / 150 V ATC-ABOC Days 24/01/07

PS EAST AREA POWER CONVERTERS u u u In operation since 1970 Electronics replacement

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

PS EAST AREA POWER CONVERTERS FAULT STATISTICS 2004 2006 Exploitation period 28 weeks 22

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

PS EAST AREA POWER CONVERTERS MAIN CONCERNS u Polarity switches : • Blocked with

PS EAST AREA POWER CONVERTERS MAIN CONCERNS u Polarity switches : • Blocked with 0 A 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 u 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 SPS North area u u u

SPS NORTH and PS EAST AREAS POWER CONVERTERS SPS North area u u u CONCLUSION 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 u u 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 PS 2? Both Areas are using old power converters with not reliable electronics => High number of First Line interventions ATC-ABOC Days 24/01/07