SC1R Cold Box PDR Controls SC1R Cold Box Preliminary Design Review R Norton Thursday, November 08, 2018

General Controls Overview Power for the new system Removal of existing cables and transformers New Breaker panel instead of a breaker ‘box’ Power for pump on secondary CW loop. Controls for the new system PLC system already exists for this purpose. Some new wiring Controls for new secondary CW loop Instrumentation for the new system Pressure transducers, feedthroughs, and tubing. SC1R PDR Controls

Control System Overview Vendor (x5) EPICS System Control Cabinet (AMB/VFD) Motor Cold Compressor Magnetic Bearings Temperature Sensor Speed Sensor EPICS OPI EPICS Servers Cryo Controls Network Switch EPICS IOCs 2K Coldbox PLC Power 120V (UPS/Normal) Instrumentation (Sensors, Valves, etc.) Digital Comms Gateway 480V/3PH) Hardwired Signals Stop, Start 40 AMPS SC1R PDR Controls

Existing Power Overview Power Feed CC1-4 480V/3PH) Power Feed CC5 480V/3PH) 100A 480-380V XFRMR 480-380V XFRMR 30A 100A Breaker Box 35A 100A 60A VFD 1 AMB1 VFD 2 AMB2 VFD 3 AMB3 VFD 4 AMB4 VFD 5 AMB5 XFRMR XFRMR XFRMR CC1 CC2 CC3 CC4 CC5 SC1R PDR Controls

Future Power Overview Breaker Panel Power Feed CC1-5 480V/3PH) 100A AMB/VFD 1 AMB/VFD 2 AMB/VFD 3 AMB/VFD 4 AMB/VFD 5 CC1 CC2 CC3 CC4 CC5 SC1R PDR Controls

Existing Controls Hardware To Be Reused Allen-Bradley ControlLogix 1756 PLC for cold box control. Takes in digital and analog I/O data Control for valves and CC remote stop signals Interface to remote display screens, Redundant 24V and PLC power supplies Fed by EM-loop and house power Backed up by a UPS Temperature diode signal conditioning Two 8-Channel Cryocon temperature monitors Ethernet connection to PLC. Vacuum control enclosure Diffusion Pump Heater and Gate Valve control based on foreline and Box pressure. SC1R PDR Controls

New Controls Hardware Required Cold Compressor Frequency Drive and Magnetic Bearing Enclosure Supplied by the Cold Compressor vendor Instrumentation junction box Pressure transducers Temperature terminals for primary/spare management Control enclosure for secondary cooling water loop pump and valve Control for solenoid valve and pump. Automatically engages solenoid valve based on a differential pressure switch. SC1R PDR Controls

Control Logic 2K system control loops remain the same. One primary PID loop for CC1-4 speed. Individual CC speeds are set by a software ‘gear ratio’ to this master speed command. Follow a pre-established pump down sequence that varies gear ratios PID loop that varies CC5 speed in order to control CC5 suction pressure. CC5 optionally can be set to have a gear ratio to the master speed, as is done for the other 4. Safety shutdown hardwired from PLC digital output directly to the VFD/Mag Bearing Allows PLC to shutdown or inhibit VFD from starting motor in the event the Digital communications interface fails A problem with one cold compressor will make the PLC shut them all down along with outlet valves. SC1R PDR Controls

The vendor will provide a suitable path. Pumpdown Path A ‘path’ must be found to pump down the system from 1 atm to ~.035 atm. This involves varying the ratio of the cold compressors with the pressure as it comes down. The vendor will provide a suitable path. Some experimentation and commissioning time will be required to perfect. SC1R PDR Controls

Cold Compressor Software Interface Digital Communications Between the PLC and motor controller/Magnetic Bearings Loss of communications should result in a trip Vendor must provide a communication signal list with sufficient breadth: Speed readback Speed command Motor/Bearing faults and status Mag bearing unbalance/current information Temperature status information SC1R PDR Controls

Electrical Cabinet Considerations Control cabinets should be located within 10 m from motors to accommodate maximum cable length Control cabinets should handle both Magnetic Bearing and VFD functionality. Control cabinets will likely not require any UPS backup, with a standard now to use the regenerated power from the wheel to power magnetic bearings in the event of power outages SC1R PDR Controls

Controls Engineering Work Required PLC Wiring details Instrumentation panel layout Controls Cable routing (rework of existing cable tray) Power Cable routing Power distribution details for 480V Tubing schematics for instrumentation PLC programming Secondary Cooling Water Loop Controls Most of these items can be copied from the LCLS2 project. SC1R PDR Controls

R Norton (757) 269-7331, norton@jlab.org Thursday, November 08, 2018