Development of the magnet power supplies at The … · power supplies at The Australian Synchrotron Sean Murphy POCPA ... to Danfysik 9100 series modules ... LTB and BTS – 49 converters

Development of the magnet

power supplies at

The Australian Synchrotron

Sean Murphy

POCPA - 2012

Introduction

• Upgrading storage ring magnet power supplies to Danfysik 9100 series modules

• Upgrade of the dipole power supply controller

• Shielding of the dipole cables

• Development of pulsed power supplies for top-up operation

Introduction

• The Australian Synchrotron (AS) is a 3GeV light source built in Melbourne, Victoria and opened on 31 July 2007.

• Storage ring 216m circumference, 14 sectors

• 200mA stored current

• Entered top-up mode on 22/05/2012!!

SR Magnet Power Supply Upgrade

• Poor reliability of the 9000 series DC power supplies since

commissioning of The Australian Synchrotron. These are in use on

all of the storage ring multi-pole magnets (up to 200A).

• Most of these faults occur during start-up and machine studies when

the magnets are cycled.

Magnet QF QD SF SD

Total number of power supplies 56 28 42 56

Total yearly failures 16 12 11 8


• The fault levels for 2011 were greatly reduced by lessening the

diagnosed fault mechanisms. This included reducing the number

and magnitude of the magnet cycles during start up and machine

studies.

Magnet QF QD SF SD

Total number of power supplies 56 28 42 56

Total yearly failures 8 8 5 4


• The 9000 series power supplies contain up to 4 separate modules,

each capable of 50A, enabling up to 200A.

• Each module is a full wave DC/AC/DC 100kHz converter utilising

two parallel H-bridges (8 MOSFETs). TI UCC3895 controller

• Common faults include:

– MOSFET failure due to asymmetric switching

– Gate driver IC failure

– Snubber circuit failure


• Improved reliability of the newer 9100 series Danfysik power supply

was proven after extensive testing.

• The 9100 series modules include key design changes including:

– Galvanic isolation using gate drive transformers

– Separate ground for control electronics

– Relocated control circuit and rerouted PCB, shortened signal paths

– Heavy duty snubber circuit


• One of the upgraded 200A units was tested at AS under laboratory

conditions to evaluate its reliability during repetitive magnet degauss

cycles. A total of 18,000 degauss cycles were completed

successfully without failure, this is equivalent to >40 years of normal

operation for a power converters.


• A typical magnet cycle program would be:

• The power supply goes to 160A for 5 seconds.

• The power supply starts at 0A for 5 seconds.


• The power supply starts at 0A for 5 seconds.


• The power supply goes to 118A for 30 seconds and repeats.


• Five upgraded power converters which consist of 4 x 200A units and 1 x

100A unit were installed in the storage ring and tested. 7,500 degauss

cycles were completed with the actual storage ring magnets, operating from

different initial conditions - OFF state, nominal output current and zero

output current. No failures of the 5 power converters were recorded.

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• It was decided to install the 9100 series modules in the 9000 series

chassis.

• The power converter fault statistics generated in December 2010

recommended an upgrade priority order as follows:

– SR F Quads – 56 converters

– SR F & D Sextupoles – 98 converters (These are high priority due to impact on

the storage ring)

– SR D Quads – 26 converters (Originally intended to be done with F Quads

upgrade)

– LINAC, LTB and BTS – 49 converters (Increased priority due to Top-up but won’t

affect beam availability statistics)

Magnet QF QD SF SD

Total number of power modules 224 56 126 168


• The final production version from Danfysik would contain different

MOSFETs and magnetic components sourced from different

suppliers.

• It was therefore decided to test and verify these production versions

with the same degauss cycling at Dankysik:


• These new units were thoroughly tested against an agreed test

procedure including 1000 degauss cycles without failure.


• All 56 SR Focus Quadrupole power converters were upgraded in

January 2012. Each unit was degauss cycled a minimum of 100

times.

• They have since been operational to present without a failure.

• Phase 2: Sept 2012 – Upgrade approximately 49 Sextupole and 14

D Quadrupole magnet power converters and procure enough power

modules to hold adequate stock of spares.

Dipole Power Supply Shielding

• 50Hz interference on the stored beam has been a problem. There is

a significant current flowing through the cable ladder that supports

the storage ring dipole power supply AC cables. It is being induced in to the parallel conductors that make up the cable ladder supports.

Min Max Avg

AIrms 4.525 4.567 4.550

BIrms 1.187 1.206 1.195

Ev ent Details/Waveforms

11:31:33.5

24/08/2011

Wednesday

11:31:33.6 11:31:33.7 11:31:33.8

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• Galvanised mild steel cable duct installed offset from the cable

ladder and earthed at one end:

Event #21 at 12/10/2011 12:01:24.039

A-BV Severe Arcing Full Cyc

Phase 362.6 Deg

Ev ent Details/Waveforms

12:01:24.1

12/10/2011

Wednesday

12:01:24.2 12:01:24.3 12:01:24.4

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Min Max Avg

AIrms 0.9414 0.9640 0.9509

BIrms 0.3945 0.4151 0.4036


• Due to the adequate shielding capabilities of the steel conduit, and

the ease with which it can be installed on the dipole power supply

AC cables, it is strongly recommended to fully shield these cables

from the power supply, to the cable gantry. This will reduce the EMF

radiated from these cables and the subsequent induced 50Hz noise

by at least 75%.

• Relocation of the dipole power supply with only the output DC

cables running across the machine to the dipole magnets would

reduce the induced current significantly; the only changing magnetic

field would be due to the ripple on the output current. This would

require a suitable location to be found, and suitable cabling and

plumbing for cooling water to be installed to this new location.

Dipole Power Supply Controller

• The existing dipole power supply controller has not been sufficient due to controller lock up and dropping of communication.

• It was decided to replace the controller with a voltage and current loop controller and a separate PLC for interlocks. There are approximately 27 interlocks.

• An Ethernet Power Supply Controller from SLAC was purchased and evaluated

Calibrate septum board between open and

closed loop operation • The Australian Synchrotron is moving to top up mode which requires

repeatable single pulses every two minutes of the septum magnets in addition to continuous 1Hz operation (8000A in 600us).

• The solution to this is to operate the septum magnet in closed loop for 1Hz, and open loop for single pulses.

• During 1Hz ‘full fill’ the system needs to be in closed loop due to temperature drift of the magnet (significantly reduced by a new heatsink) and open loop during ‘top-up’ pulses due to the duration of time between pulses.

• The septum had to be calibrated to bring closed loop operation to within approximately 200ppm of the open loop single pulses. The power supplies were originally rated to ±500ppm.

• A trim pot was used to bring the closed-loop output current to within calibration of the open loop by biasing the error


closed loop operation

• Automatic Open-Loop to Closed-Loop change over board was

designed and installed. This allows level operation at 1Hz followed

by level operation with single pulses with automatic change-over.



• The septum was run in continuous 1Hz closed-loop operation for 10

minutes, and then one open-loop single pulse every two minutes for

20 minutes (10 single pulses). The calibration difference between

open and closed loop was adjusted to a maximum difference of

212ppm.

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Sample and hold voltage

Heat sink on the septum magnet yoke

• Due to the thermal drift of the septum magnet, it was decided to

install a heat sink on the yoke of the magnet.

• This reduced the long term drift from a 35A drift over six hours to a

16A drift over 45 minutes

Heat sink on the septum magnet yoke

Shielding of the Septum Magnet controller

• Due to the interference cause by KE-2 operating, the output current

could deliver false read back and could vary by up to 5000ppm

during 1Hz operation. The calibration difference between open and

closed loop was up to 4000ppm.

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Sample and hold voltage - kicker running - no shielding


• The interference was caused by radiated high frequency noise from

the nearby kicker (600A in 200ns) being picked up by the SEE-2

controller board PCB and associated cabling. The current feedback

had the following high frequency spike observable when the kicker

was operating:

• The electrical noise has a peak of approximately 8V above the DC

offset at approximately 30MHz


• The nature of the noise was determined to be radiated high

frequency EMI from KE-2, to mitigate the interference on SEE-2 it

was decided to install shielding on the SEE-2 control board and

cables.


• Due to the shielding, the noise on the sample and hold reduced from

approximately 8Vpeak to 0.476Vpeak.


• The maximum calibration difference between open and closed loop,

with KE-2 operating and shielding installed, is approximately

±250ppm. However, it is typically ±100ppm between open and


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Sample and hold voltage - kicker running - with shielding

Septum Magnet induced currents

• A significant current was being induced in to the vacuum vessel by

the septum magnets. There was no defined return path for this

current creating peak currents of over 30A in the surrounding

conductors. This created problems with diagnostic equipment such

as the fast current transformers (FCTs)


• With a copper braid installed from the vacuum vessel to the

aluminium yoke support, the current through the new braid was in

excess of 400A peak


• Results: With two septum magnets running (SEP-3 and SEI-3) the

currents through four FCTs positioned around the injection system

were measured: LTB FCT (green), Booster FCT (yellow), BTS FCT1

upstream (pink) and BTS FCT2 downstream (purple). Both before

and after installation of the braids to the vacuum vessel.

Before After

Kicker Magnet return path

• Originally by design, the return current passed down

vacuum vessel.

• There were other parallel return paths (earth loops)

which caused current to flow throughout the earthing

system and vacuum vessel.

• A better design would be a single connection to earth

and a dual feed through design to keep the magnet

conductor floating.

• The HV is at 18kV and 4kV across the vacuum vessel

was measured.

• Thyratron pulse at 1Hz, 600A peak for 200ns; total time

500ns

Kicker Magnet shielding

• Existing enclosure:


• A new kicker enclosure was constructed:

– 3mm aluminium

– Alodine finish for conductivity / surface passivation


• RF gaskets and fingers installed on all openings


• Shielding and RF fingers around the vacuum vessel:


Completed and

installed

enclosure:


• Completed and installed enclosure around the vacuum vessel:

Before After


• Results: • The peak to peak magnitude of the noise is approximately 40% of

what it was with the old enclosure.

Before After

New Development – Fast Global Feedback

• Looking at developing in-house low current linear power

supplies with analogue control for the purpose of fast

global feedback.

• FGF has the aim of reducing noise and taking the 50Hz

out of the beam.

• The sextupole yokes may have additional windings

added for the purposes of FGF, so as not to effect the

existing correctors.

• This is still being investigated.

Acknowledgements

• Steve Griffiths

• Wes Hoffman

• Brian Jensen

• Adam Michalczyk

• Noel Basten

• And the rest of the electrical team

Documents

Development of the magnet power supplies at The … · power supplies at The Australian Synchrotron Sean Murphy POCPA ... to Danfysik 9100 series modules ... LTB and BTS – 49 converters