Magnetic Measurements Upgrade Safety Tutorial

1
Magnetic Measurements Upgrade Safety Tutorial
J.J. Lipari, Sept. 2007
2
Improvement Project with Safety Requirements

• Fabricate, install one new rack with 3 new 15 kW
  480 VAC input power supplies and their
  controllers and Danfysik transductors
• Integrate the 3 new rack mounted 15 kW supplies
  into magnet interlock and Mag. Meas. Control
  system
• Integrate the 3 new supplies into existing Link
  box
• Include existing 60 kW and 20 kW EMHP (floor
  mounted) power supplies in the new installation,
  with new controllers, Link Box connections and
  magnet interlocks
• Install new 480 VAC 3-phase power panel, and run
  power to new rack (with the 3 new 15 kW supplies)
  and the 2 EMHPs

3
Improvement Project With Safety Requirements

• 6. Bring the existing double rack with new
  208/120 VAC service for control power up to NEC
  standards, including grounding and bonding.
• Remove obsolete chassis from existing double
  rack, install new interlock, control chassis,
  transductors for the 2 EMHPs
• Install new cable tray for DC cabling for 3 new
  15 KW and 2 existing EMHP power supplies to Link
  Box (safety requirement to satisfy latest NEC
  requirements)
• All 5 new supplies use the Integrated ZFT
  Regulator/controller, SD 236-250-00

4
New Rack Profile
5
New Installation Plan
6
Power Supply/Magnet Test Configuration
7
New 480V Panel 5B1A10-3
8
480 VAC Feeder Breaker (Panel 5B1A10) for 15 KW
and EMHP Supplies
9
Rack 01 Showing New 280/120 VAC Breaker
10
Operation of Magnetic Measurements Installation

• The 3 original large 120VDC/1200A/144 KW supplies
  still part of system
• The 5 new power supplies now also part of Link
  Box and magnet interlock patch panel system
• 5 new supplies include PS4 (200V/75A/15KW), PS5
  (30V/500A/15KW), PS6 (40V/375A/15KW), all rack
  mounted and PS7 (80V/250A/20KW EMHP) and PS8
  (150V/350A/60KW EMHP)
• All 5 new supplies have 480 VAC inputs, fed by 5
  circuit breakers in Panel 5B1A10-3 on column next
  to racks
• Panel 5B1A10-3 fed from one circuit breaker on
  Panel 5B1A10 on column across from 144KW supplies

11
Operation of Magnetic Measurements Installation

• Any one of the 8 power supplies can be connected
  to any one of 6 test areas by using the Link Box
  and the links provided
• Any one of the 8 power supply controllers can be
  patched to the magnet interlocks of any of the 6
  test areas
• Opening the Link Box or any one of the 6 Test
  Area cabinets will break the interlock chain and
  all power supplies will trip off
• Always lock and tag the 480 VAC breakers on all 3
  144 KW supplies (on front of each PS) plus the
  480 VAC breakers for the 5 new supplies,
  following the posted Equipment Lock and Tag
  Procedures
• The ELPs for the 5 new supplies are SR
  526-706-01 through SR 526-706-05, with an ELP SR
  526-706-06 for the Link Box itself
• Magnetic Measurements techs must follow the Link
  Box ELP, SR 526-706-06 when opening the Link Box
  or opening any test area terminal cabinet. PEM
  techs who need to open the Link Box or any Test
  Area cabinet also need to follow this ELP

12
Operation of Magnetic Measurements Installation

• After opening the link Box, perform ZVV on all 16
  PS terminal buss bars. If on any PS terminal in
  the Link Box, you measure any more than 10 VDC
  that does not appear to be discharging, close the
  Link Box doors and call PEM
• For now, when opening the Link Box, after
  performing ZVV, you must use the ground hooks to
  discharge all 16 power supply output buss bars
  (they are labeled). Keep the ground hooks on the
  PS terminals to which you wish to make
  connections
• Larger links (1500 ampere rated) are to be used
  only for power supplies 1,2 , and 3, the 144 KW
  units. The rest, PSs 4 through 8, use the
  smaller 500 MCM links
• There is a complete set of EI drawings EI
  526-706-01 through EI 526-706-05 for power
  supplies 5 through 8 for the 3 144 KW units
  there is one EI drawing, EI 526-703-21
• PEM technicians are to use the individual ELPs
  for each power supply when performing any repair
  work on any of the power supply systems. PEM
  techs are also required to obtain permission from
  the Magnetic Measurements lab supervisor before
  performing any task in the MM lab

13
Modified Link Box (shown open)
14
Details of Link Box Operation

• All 8 power supplies (three 144 KWs, three 15
  KWs, two EMHPs) all cabled to Link Box to 16
  vertical busses (plus and minus)
• 12 horizontal busses connect to the 6 test areas
• All 8 PSs can be connected to any one of 6 Test
  Areas via 1500A or 500 A links
• Connect the original three 144 KW, 1200 A
  supplies to any test area using the big 1500A
  links connect the 15 KW and EMHPs using the
  smaller 500MCM links
• Always patch the right Test Area magnet
  interlocks to the right power supply using the
  Interlock patch panels in Racks 1 and 2