steve lewis [email protected] xtod controls fdr 13 march 2008 xtod vacuum controls final...

Steve [email protected] Controls FDR

13 March 2008

XTOD Vacuum ControlsFinal Design Review

Steve Lewis/Keith Kishiyama13 March 2008


13 March 20082

Some Guidelines

Re-use existing LCLS or planned XES technology when feasible

Lower cost and schedule riskReduce maintenance cost and overall complexity

Else use SNS technology as ‘best-practices’ exampleRecent; working; EPICS-based

FEE has very limited physical space, but ‘acceptable’ radiation levels

Place short racks under beamline (with short cable runs) for instruments

Use full-height racks in alcove for vacuum controllers

XRT will use short racks for vacuum


13 March 20083

Introduction

There are three types of systems‘Standard’ beamlineDiagnostic ‘tanks’ (for instruments)High pressure/high flow regions (gas detector/gas attenuator)

PLC vs EPICSPLC will provide protection (basic interlocking) using direct signals (analog, digital)EPICS will provide sequencing (via PLC and serial communications to controllers)

LCLS Standards will be indicated with: √


13 March 20084

Common Items

Allen-Bradley for PLCCLX-5000/1756 chassis for PLC √

Ethernet and Ether/IP for IOC communication √ControlNet for outboard I/O communication √1 for FEE Gas Flow; 1 each for FEE, NEH, XRT vacuum

For ‘logical’ independence

Flex-I/O for I/O pointsInexpensiveBuilt-in screw terminals (simple)Mounted vertically in racks with co-located controllers

1 for FEE Gas Flow; 3 for FEE; 1 for each NEH Hutch; 5 for XRT; 1 for FEH

VAT VF-2 Fast Shutter between Dump and FEEBi-directional protectionVendor supplied sensors, shutter, cables


13 March 20085

Common Items

‘Cross-over’ Valve LogicThe PLC that controls it needs a pressure indication ‘from the other side’Use two signals: 1/0 => HV; 0/1=>atmos; 0/0 and 1/1 => no power, disconnected cable, etcPLC can resolve permission-to-open logic for any case


13 March 20086

Machine Protection SystemEach PLC summarizes status of items that can intercept beam;

Isolation valves must be OUTApertures must be IN or OUTMPS gets ‘OK’ if all of above are TRUE (‘and-operation’)Wired to MPS node in NEH hall with 24V pairSignals list:

PLC:FEE1:E101VVPG:DMP1:881 FstShtVVPG:FEE1:111 FstShtVVPG:FEE1:421 KSVVPG:FEE1:451 TEVVPG:FEE1:481 DIVVPG:FEE1:761 HOMSVVPG:FEE1:861 HOMSVVPG:FEE1:1721 SOMSVVPG:FEE1:1791 SOMSVVPG:FEE1:2831 SOMSVVPG:FEE1:1831 SOMSVVPG:NEH1:131 NEHVacVVPG:NEH1:2131 NEHVacVVPG:NEH1:1131 NEHVac

PLC:FEE1:E202VVPG:FEE1:201 GasAttVVPG:FEE1:211 GasDetVVPG:FEE1:221 GasDetVVPG:FEE1:231 GasDetVVPG:FEE1:241 GasDetVVPG:FEE1:251 GasAttVVPG:FEE1:261 GasAttVVPG:FEE1:311 GasAttVVPG:FEE1:341 GasAttVVPG:FEE1:351 GasAttVVPG:FEE1:361 GasDetVVPG:FEE1:371 GasDetVVPG:FEE1:381 GasDetVVPG:FEE1:391 GasAtt

PLC:NEH1:203VVPG:NEH1:291 NEHVacVVPG:NEH1:2211 NEHVac

PLC:XRT1:104VVPG:XRT1:111 TnlVacVVPG:XRT1:5251 TnlVacVVPG:XRT1:5611 TnlVacVVPG:XRT1:5991 TnlVac

PLC:FEH1:505VVPG:FEH1:5441 FEHVac


13 March 20087

Block Diagrams


13 March 20088


13 March 20089


13 March 200810

Controller Summary

FEE:1 Shutter, 9 Ion, 5 Scroll, 9 Turbo, 17 Gauge, 5 Pressure

13 Isolation/Gate Valves, 26 Rough/Fore/Bypass Valves

NEHH1: 2 Ion, 2 Gauge; 3 Isolation Valves

H2: 1 Ion, 1 Gauge; 2 Isolation Valves

H3: 1 Ion, 1 Gauge [probably not in scope]

XRT4 Ion, 4 Gauge; 3 Isolation Valves

FEH1 Ion, 1 Gauge; 1 Isolation Valve


13 March 200811

Cable Summary

FEE:5 Shutter, 16 Ion, 5 Scroll, 9 Turbo, 39+23 Gauge, 9 Pressure39 Valve

NEHH1: 3 Ion, 6 Gauge; 3 ValveH2: 2 Ion, 4 Gauge; 2 ValveH3: 1 Ion, 2 Gauge [probably not in scope]

XRT8 Ion, 16 Gauge; 3 Valve

FEH1 Ion, 2 Gauge; 1 Valve


13 March 200812

‘Standard’ Beamline

Expect steady-state operationMostly HV (~10-6); some UHV (~10-10)Manual valve and roving cart for roughing/venting √

Not part of control system

HardwareGamma MPC-2-100 dual Ion Pump HV supply √

One pump per supply9 in FEE; 3 in NEH

MKS 937A Gauge Controller √Two pairs of Convectron-Enhanced Pirani + Cold Cathode10 in FEE; 3 in NEH

Sequences: none


13 March 200813

Process Diagram

Ion Pump

(Isolation) Gate Valve

Convection-Enhanced Pirani GaugeCold Cathode Gauge

Manual Cart Valve


13 March 200814

Interconnect DiagramIO

C

Gauge Controller

Ion Pump Controller

Analog andDigital Signals

Beamline

Gate Valves

Ion Pump

Pirani + Cold Cathode Gauges

Gate Valve I/O

Eth

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Con

t ro

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t I n

ter f

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Flex I/O

ControlNet

PL

C

RS-232

RS-232

LadderLogic

Eth

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t Int

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Con

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Ethernet (Channel Access VLAN)

TerminalServer

Ethernet (Field-bus VLAN)


13 March 200815

Diagnostic Tanks

Three instruments: Direct Imager, Total Energy,K-SpectrometerExpect many pump/vent cycles

HV (~10-6)Valved Turbo/scroll pump for roughingVent valve with clean N2 for up-to-atmosphere

Hardware (each instrument)Gamma MPC-2-100 dual Ion Pump HV supply √

One pump per supply (can be shared by 2 instruments)MKS 937A Gauge Controller √

Two pairs of Convection-Enhanced Pirani + Cold CathodeVarian V-81 Turbo-molecular Pump/ControllerVarian SH-110 Scroll Pump/Remote AC Contactor

Sequences: Pump↔Vent


13 March 200816

Process Diagram

Ion Pump

(Isolation) Gate Valve

Convection-Enhanced Pirani GaugeCold Cathode Gauge

Vent Valve

Roughing Valve

Turbo Pumpw/vent valve

Scroll Pumpw/fore valve


13 March 200817

Process DiagramIO

C

Gauge Controller

Ion Pump Controller

Turbo Pump Controller


Beamline

Valves

Ion Pump

Turbo Pumps

Pirani + Cold Cathode Gauges

Gate Valve I/O

Eth

erne

t Int

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Con

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t I n

ter f

ace

Flex I/O

ControlNet

Scroll Pumps

Scroll pump control

PL

C

RS-232

RS-232

Magnetic Starter

LadderLogic

RS-232

Eth

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t Int

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Con

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ter f

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Ethernet (Channel Acces VLAN)

TerminalServer



13 March 200818

Gas Pressure/Flow Three sections: Upstream Gas Detector, Gas Attenuator, Downstream Gas Detector

Each has independent pressure set-point, with differential pumping to enclosing beamline, and shared differential pumping between them

Three modes:HV open to match beam lines (all apertures retracted)Vented (all apertures retracted)Independent pressure set-points (all apertures inserted)

~few mT to ~20T of N2

Hardware2 each MKS146C, PR-4000, MKS-649, PRD-2000 pressure/flow controllers 7 MKS 937A Gauge Controller ✓

Each 4 Convection-Enhanced Pirani +1 Cold Cathode2 each Varian 301, 701, 1001 Turbo-molecular Pump/Controller6 Varian 600DS Scroll Pump/Remote AC Contactor2 Kashiyama MU100 Screw Pump

Sequences: Flow↔HV↔Vent


13 March 200819

Process Diagram

(Isolation)Gate Valve

Convection-EnhancedPirani Gauge

Roughing Valve Roughing Valve

Turbo Pumpw/vent valve

Scroll Pumpw/fore valve

Screw Pump

Aperture

Cold CathodeGauge

Aperture

Pressure/Flow Valve

x6x2x3

BaratronGauge


13 March 200820

Process DiagramIO

C

Gauge Controller

Pressure Controller

Turbo Pump Controller


Beamline

Gate Valves

Pressure/Flow Units

Turbo Pumps

Pirani + Cold Cathode + Baratron Gauges

Gate Valve I/O

Eth

erne

t Int

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ce

Con

t ro

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t I n

ter f

ace

Flex I/O

ControlNet

Scroll + Screw Pumps

Scroll pump control

PL

C

RS-232

RS-232

Magnetic Starter

LadderLogic

RS-232

Eth

erne

t Int

erfa

ce

Con

t ro

lNe

t I n

ter f

ace

Ethernet (Channel Acces VLAN)

TerminalServer



13 March 200821

Racks & Power40U/80″

1 Triple Bay for FEE Instruments + Gas Flow1 for SOMS

24U/42″ Under beamline1 for HOMS; 6 for XRT

Rack power distributionFurman unit with 100A input; 1 in each 24U rack; 2 in 40U double rack √


13 March 200822

SoftwareEPICS √

Base, extensions shared with XTOD Instrument controls √Modules:

Ether/IP added for IOC-to-PLC √

IOC will run in either Linux (soft) or 1-U Dawn/RTEMS √

ApplicationsPLC ladder logic does pure interlocking, using analog/digital signals All commands/response from/to EPICSEPICS sequencers will provide all vacuum (pump/valve) sequences; and they will control pressure set-points for gas flow


13 March 200823

Photos of Ongoing Fabrication at LLNL


13 March 200824

Prototype of Flex-I/O Wiring


13 March 200825

Partly Loaded

Main FEE Rack

(front)


13 March 200826

Partly Loaded

Main FEE Rack (rear)


13 March 200827

References

Complete Spreadsheet of all PVs, controllers, racks, VME boards, etc:

http://www.slac.stanford.edu/grp/lcls/controls/systems/xray_transport/Sheets/XTOD-Controls-Planning.pdf

Complete Block Diagram:http://www.slac.stanford.edu/grp/lcls/controls/systems/xray_transport/Diagrams/XTOD-Vacuum.pdf


13 March 200828

Complete book of wiring diagrams available

steve lewis [email protected] xtod controls fdr 13 march 2008 xtod vacuum controls final...

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