A.3 Technical Specification.pdf

Electron-Ion Collider, Brookhaven National Laboratory

Doc No. EIC-PSG-SPC-001 Author: D. Prevosto Effective Date: August 30,2024 Review Frequency: N/A

Specification Title: 187.5A Unipolar EIC ESR Quad Power Supplies Revision: 00

TECHNICAL SPECIFICATION

for the

187.5A Unipolar EIC ESR Quad Power Supplies

Quality Classification: A-3

Prepared By:

_________________________________ Date: __________________ D. Prevosto, Associate Electrical Engineer

Reviewed By:

C. Galdamez, Procurement Liaison Engineer

J. Zipper, Quality Assurance Representative

Approved By:

D. Bruno, Power Supply Group Leader

Docusign Envelope ID: 8C5F5C94-BC97-446C-93B5-E594292CC9C3

9/4/2024

9/9/2024

9/4/2024

9/9/2024

Doc No EIC-PSG-SPC-001 Author: D. Prevosto Effective Date: August 30,2024 Review Frequency: N/A

This page intentionally left blank, to accommodate back-to-back printing.

REVISION HISTORY

Revision # Effective Date Summary of Change

00 8/30/2024 Initial Release

Table of Contents

LIST OF ACRONYMS

1 SCOPE

1.1 Background

2 APPLICABLE DOCUMENTS

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

3.2 Warranty

3.3 Schematics

3.4 Environment, Safety and Health

4 VERIFICATION

4.1 Classification of Inspections

4.2 Inspection/Testing Details/Requirements

LIST OF ACRONYMS

ASME American Society of Mechanical Engineers BNL Brookhaven National Laboratory BSA Brookhaven Science Associates COTS Commercial Off-The-Shelf EIC Electron-Ion Collider

EMC

ESD

Electromagnetic Compatibility Electrostatic Discharge

ESH Environment, Safety and Health ESR Electron Storage Ring NEC National Electric Code

SELV

Safety Extra Low Voltage

187.5A Unipolar EIC ESR Quad Power Supplies

1 SCOPE

This specification defines the technical requirements for a power supply that can provide 80 volts and 187.5 amperes to be used at the Electron-Ion Collider (EIC) at Brookhaven National Laboratory (BNL) managed by Brookhaven Science Associates (BSA).

1.1 Background

The EIC Project will design, build, and install the accelerator hardware for a new electron storage ring (ESR), an electron injector, and modifications to the hadron ring required to produce an electron ion collider and infrastructure. It will include one interaction region, with an allowance for a second, and one detector. The facility is designed to meet requirements to ensure high reliability and availability for the user program.

The ESR will be using many Commercial Off the Shelf (COTS) Power Supplies. In some cases, we will be putting these power supplies in series to achieve a higher voltage and in other cases we will be putting these power supplies in parallel to achieve higher currents. For this procurement, we will be using the power supplies in both series and parallel.

2 APPLICABLE DOCUMENTS

The following specifications, standards and drawings form a part of this specification to the extent specified herein. Unless otherwise specified, the issues of these documents shall be that in effect on the date of the solicitation or contract. Exceptions must be approved in writing by BSA.

In the event of a conflict between the applicable documents and this specification, the Contractor shall immediately notify the BSA Contractual Representative who shall in each instance determine which document takes precedence and advise the Contractor accordingly. Failure to notify BSA of a document conflict shall not relieve the Contractor’s responsibility to ensure full compliance to all requirements.

Document Number Document Title

IEC/EN61000 Standards for Power Supplies

EN55011 Industrial, scientific and medical equipment - Radio-frequency disturbance characteristics - Limits and methods of measurement

3 REQUIREMENTS

3.1 Technical/Performance Characteristics

Table I: Input Characteristics AC Input Voltage Range 432Vac-528Vac 3-phase AC Input Voltage Frequency Range 47-63 Hz Input Current max at 432VAC 27A Input Current max at 528VAC 22A Power Factor 0.88 Efficiency 88% Switching Frequency input stage 66kHz (typical)

EMC ESD EN61000-4-2

EMC Radiated Immunity EN61000-4-3 EMC Fast Transients EN61000-4-4 EMC immunity to Surges EN61000-4-5 EMC Conducted Immunity EN61000-4-6 EMC Conducted Emissions EN55011A Voltage Dips, Short Interruptions, and IEC 61000-4-11 Voltage Variations Immunity Test (400VAC Only) Power Frequency Magnetic Field; 30A/m EN61000-4-8 EMC Radiated Emissions EN55011A Input leakage currents 3.5mA max Input Hi pot voltage Ground: 2900VDC (60s) SELV: 2900VDC (60s) Output (Haz): 3500 VDC (60s)

Table II: Output Characteristics

Output Voltage Range 0 - 80VDC rated Output Current Range 0 - 187.5ADC rated Closed Loop gain Voltage Channel 8 Closed Loop gain Current Channel 18.75 Power Supply Topology Unipolar Switchmode Regulation Voltage or Current Regulation Quadrants of operation 1 quadrant (positive voltage and positive current) Switching frequency of output stage 198kHz (typical)

Output ripple at rated power (p-p, 20 MHz) = 100mVp-p (RMS, 5Hz-1MHz) = 25mVrms Voltage Ripple CV = 25mVrms (5Hz – 1MHz) CC = 100mArms (5Hz – 1MHz) Source Adjustment Range Voltage (0C-50C) 0% to +100% of rating Source Adjustment Range Current (0C-50C) 0% to +100% of rating Analog programming Source 0 to +10VDC for voltage and current mode Analog voltage readback 0 to +10VDC Analog current readback 0 to +10VDC Analog Programming Accuracy

a) Voltage +/-1.5% of rating

b) Current +/-1.5% of rating

Notes:

i. Programming signal is 0V to +10V for + Vps out max or +Ips out max

ii. Input impedance is 1Mohms for the main channel (voltage or current)

iii. When limit channels are not used, the limits are clamped to 1% above nominal values.

Analog Readback Accuracy

a) Voltage 0.1%

b) Current 0.1%

Notes:

i. Analog readback is 0 to +10V for voltage and current maximum ps ratings

ii. Output impedance of analog readback signal is 100ohm

iii. The output current max is 5mA

Voltage Stability in voltage mode

a) Source effect (min-max input rating) 0.05% of rating

b) Load effect (0-100% load current) 0.05% of rating

c) Time effect (drift, 0.5-8 hrs) +/-0.05% of rating

d) Temperature effect(0C-50C) 0.02%/oC of max rating

Current Stability in current mode

a) Source effect (min-max input rating) 0.05% of rating

b) Load effect (0-100% load current) 0.075% of rating

c) Time effect (drift, 0.5-8hrs) 0.05% of rating

d) Temperature effect(0C-50C) 0.003%/oC of rating

e) Ripple and Noise 100mArms (5Hz - 1MHz)

Transient recovery in voltage mode

a) Nominal voltage, 50% load step To recover within 2% of

Vo(rated)

b) Recovery time >3ms

Output Insulation Coordination Installation Category II, Overvoltage Cat II Output Isolation Voltage and leakage current.

a) Each output terminal to chassis ground +/- 600V Isolated (+/-600V) analog inputs and readbacks -5V/0-10V signals for programming and readback Remote Digital programming RS-232/RS-485 Output Protection Limiting Analog Voltage and Current limit in 1 quadrant Power Supply Protection

a) Output Overvoltage/overcurrent, Internal overvoltage, undervoltage heatsink overtemperature, switchers overcurrent, fan fail, AC FAIL, AC Phase Loss/ Imbalance, ENA, SO

Series Operation (Master/Slave) Up to 2 identical units with external diodes Parallel Operation (Master/Slave) Up to 4 identical units Basic or Advanced Parallel Small signal Voltage Loop Bandwidth 100Hz minimum 800Hz - 1200Hz (rated, resistive load, nominal AC Input)

a) into resistive load, 10% of rating 800Hz-1200Hz (typical value, resistive load, nominal AC Input)

Small signal Current Loop Bandwidth 100Hz - 400Hz (rated, resistive load, nominal AC Input)

a) into short circuit, 10% of rating 100Hz-400Hz (typical value, resistive load, nominal AC Input)

Rise/Fall time

a) Up-prog response time full load 100ms

b) Up-prog Response time no load 50ms

c) Down-prog response time full load 100ms

Over Voltage Protection

a) Programming Accuracy +/- 5% of rating

b) Trip Point 105% of rating

c) Response time <10ms(for Output to begin to drop) Over Current Protection 0-100% Constant Current Remote Analog Controls and Signals

a) CV signal TTL high, max source current = 10mA

b) CC signal TTL low, max sink current = 10mA

c) Remote/Local Control Selects Remote or Local operation by Voltage 0-0.6V = Local, 2-15V = Remote

d) Remote/Local Signal Open collector: Local = Open (Max voltage = 30V), Remote = On (Max sink current 10mA)

Voltage (CV) and Current Analog Error-Amplifier Based (CC) Feedback Loops Feeback only Isolated Analog Interface True “Analog Interface with no A/D or A/D conversion or digital isolators Operating Temperature 0C to +50C Storage Temperature -20C to +70C Cooling Fan driven air flow front to rear Humidity (non-condensing) Operating: 20% to 80% RH Storage: 10% to 90% RH Altitude Operating: +50°C up to 6562ft (2000m), Derate Iout 2%/100m up to 3000m or 1°C/100m up to 3000m, Non- Operating 40,000ft(12,000m) Dimensions (HxWxD) 5.22” x 16.9” x 22.2” Weight (maximum) 100 lbs NRTL approval required EN/IEC/UL/cUL 61010-1 or BNL approved equivalent

3.2 Warranty

The power supplies shall be warrantied for a period of five years from date of delivery to be free from defects in materials and workmanship and to conform to the specifications furnished or approved by the Contractor. Liability under this warranty shall be limited to the repair or replacement of any defective product at the Contractor’s option.

This warranty shall not extend to any product which has been subjected to misuse, neglect, accident, improper installation, or use in violation of instructions furnished by the Contractor. The warranty shall not extend to, or apply to, any unit which has been repaired or altered outside of the Contractor’s factory by persons not expressly approved by the Contractor.

3.3 Schematics

The Contractor shall provide schematics if either the Contractor refuses to repair the product in accordance with the warranty or if the Contractor no longer offers out of warranty repair services.

3.4 Environment, Safety and Health

Identification of hazards, and their mitigation, shall take place during all stages of the life of the Equipment including; installation, commissioning, operation, maintenance, and repair Identification of means to eliminate or manage each hazard shall be provided based on the following hierarchy:

• Eliminate the hazard, or manage the hazards in the following hierarchy;

• Substitute with something less hazardous, or

• Engineer – mitigate the severity of the hazard, or

• User Personal Protective Equipment (least desirable).

Quality Assurance and Facility Access

The Contractor shall maintain and apply an effective and documented quality assurance system for the design, manufacture, and testing of all equipment provided. Post-award surveys may be required and shall be supported by the Contractor. In addition, BSA representatives shall have access to the Contractor’s facility during agreed-upon fabrication, inspection, and testing processes. The Contractor shall provide ten (10) working days’ notice in advance of the agreedupon witness points. As set forth in BSA Form BNL-QA-101, “Brookhaven National Laboratory Supplier Quality Assurance Requirements,” as amended herein, forms a part of this statement of work. Specifically, this includes the following sections: 1, 2, 3, 3.1, 3.1.2, 3.2 to 3.22, 4.0, 4.1, 4.2, 4.3 ,4.4 , 4.4.1, 4.4.2, 4.4.3, 4.5, 4.6, 4.7, 4.7.1, 4.7.3, 4.10, 4.10.1, 4.10.2, 4.10.3 4.10.4, 4.11, 4.13, 4.14, 4.16, 4.19, 4.21, 4.34, 4.35, 4.36, 4.37, and 4.39. With each Component delivered, the Contractor shall supply to BSA a Certificate of Conformance, in accordance with section 4.16 of BNL-QA-101

4 VERIFICATION

Appropriate inspection/tests shall be performed to ensure equipment conforms to all requirements in section 3 of this specification.

4.1 Classification of Inspections

Items covered by this specification shall be subjected to the following tests to determine compliance with all applicable requirements:

• Power supply testing is used to verify the design, construction, and performance of the equipment.

• Testing shall include all tests of section 4.2.

4.2 Inspection/Testing Details/Requirements

All the tests outlined below shall be performed by the Contractor at their facility.

• High Potential Testing of DC terminals to ground of minimum 600V.

• The front panel ON/OFF and the rear panel enable/disable shall be tested in both local and digital remote modes. The rear panel remote analog local/remote control and signal shall also be tested.

• The rear panel remote analog enable/disable feature shall be tested.

• The isolated remote analog setpoint and the isolated remote analog readbacks shall be tested at different voltage and current levels determined by the Contractor.

• The power supply output voltage and current shall be tested at 50% and 100% of the output rated values.

• The line/load regulation shall be tested in both voltage mode and current mode.

• The ripple (peak to peak) shall be tested in voltage mode and the ripple (rms) shall be tested in current mode.

• The AC low line protection trip point shall be tested.

• The front panel’s operation shall be checked.

• The communication ports shall be tested.

• There shall be a burn-in test performed with a duration determined by the Contractor.