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XTOD Vacuum Controls Final Design Review. Steve Lewis/Keith Kishiyama 13 March 2008. Some Guidelines. Re-use existing LCLS or planned XES technology when feasible Lower cost and schedule risk Reduce maintenance cost and overall complexity Else use SNS technology as ‘best-practices’ example

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Xtod vacuum controls final design review

XTOD Vacuum ControlsFinal Design Review

Steve Lewis/Keith Kishiyama

13 March 2008


Some guidelines
Some Guidelines

  • Re-use existing LCLS or planned XES technology when feasible

    • Lower cost and schedule risk

    • Reduce maintenance cost and overall complexity

  • Else use SNS technology as ‘best-practices’ example

    • Recent; 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


Introduction
Introduction

  • There are three types of systems

    • ‘Standard’ beamline

    • Diagnostic ‘tanks’ (for instruments)

    • High pressure/high flow regions (gas detector/gas attenuator)

  • PLC vs EPICS

    • PLC 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: √


Common items
Common Items

  • Allen-Bradley for PLC

    • CLX-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 points

      • Inexpensive

      • Built-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 FEE

      • Bi-directional protection

      • Vendor supplied sensors, shutter, cables


Common items1
Common Items

  • ‘Cross-over’ Valve Logic

    • The 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, etc

    • PLC can resolve permission-to-open logic for any case


Machine protection system
Machine Protection System

  • Each PLC summarizes status of items that can intercept beam;

    • Isolation valves must be OUT

    • Apertures must be IN or OUT

    • MPS gets ‘OK’ if all of above are TRUE (‘and-operation’)

    • Wired to MPS node in NEH hall with 24V pair

    • Signals list:

PLC:FEE1:E101

VVPG:DMP1:881 FstSht

VVPG:FEE1:111 FstSht

VVPG:FEE1:421 KS

VVPG:FEE1:451 TE

VVPG:FEE1:481 DI

VVPG:FEE1:761 HOMS

VVPG:FEE1:861 HOMS

VVPG:FEE1:1721 SOMS

VVPG:FEE1:1791 SOMS

VVPG:FEE1:2831 SOMS

VVPG:FEE1:1831 SOMS

VVPG:NEH1:131 NEHVac

VVPG:NEH1:2131 NEHVac

VVPG:NEH1:1131 NEHVac

PLC:FEE1:E202

VVPG:FEE1:201 GasAtt

VVPG:FEE1:211 GasDet

VVPG:FEE1:221 GasDet

VVPG:FEE1:231 GasDet

VVPG:FEE1:241 GasDet

VVPG:FEE1:251 GasAtt

VVPG:FEE1:261 GasAtt

VVPG:FEE1:311 GasAtt

VVPG:FEE1:341 GasAtt

VVPG:FEE1:351 GasAtt

VVPG:FEE1:361 GasDet

VVPG:FEE1:371 GasDet

VVPG:FEE1:381 GasDet

VVPG:FEE1:391 GasAtt

PLC:NEH1:203

VVPG:NEH1:291 NEHVac

VVPG:NEH1:2211 NEHVac

PLC:XRT1:104

VVPG:XRT1:111 TnlVac

VVPG:XRT1:5251 TnlVac

VVPG:XRT1:5611 TnlVac

VVPG:XRT1:5991 TnlVac

PLC:FEH1:505

VVPG:FEH1:5441 FEHVac



Controller summary
Controller Summary

  • FEE:

    • 1 Shutter, 9 Ion, 5 Scroll, 9 Turbo, 17 Gauge, 5 Pressure

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

  • NEH

    • H1: 2 Ion, 2 Gauge; 3 Isolation Valves

    • H2: 1 Ion, 1 Gauge; 2 Isolation Valves

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

  • XRT

    • 4 Ion, 4 Gauge; 3 Isolation Valves

  • FEH

    • 1 Ion, 1 Gauge; 1 Isolation Valve


Cable summary
Cable Summary

  • FEE:

    • 5 Shutter, 16 Ion, 5 Scroll, 9 Turbo, 39+23 Gauge, 9 Pressure

    • 39 Valve

  • NEH

    • H1: 3 Ion, 6 Gauge; 3 Valve

    • H2: 2 Ion, 4 Gauge; 2 Valve

    • H3: 1 Ion, 2 Gauge [probably not in scope]

  • XRT

    • 8 Ion, 16 Gauge; 3 Valve

  • FEH

    • 1 Ion, 2 Gauge; 1 Valve


Standard beamline
‘Standard’ Beamline

  • Expect steady-state operation

    • Mostly HV (~10-6); some UHV (~10-10)

    • Manual valve and roving cart for roughing/venting √

      • Not part of control system

  • Hardware

    • Gamma MPC-2-100 dual Ion Pump HV supply √

      • One pump per supply

      • 9 in FEE; 3 in NEH

    • MKS 937A Gauge Controller √

      • Two pairs of Convectron-Enhanced Pirani + Cold Cathode

      • 10 in FEE; 3 in NEH

  • Sequences: none


Process diagram
Process Diagram

Cold Cathode Gauge

Convection-Enhanced Pirani Gauge

(Isolation) Gate Valve

Manual Cart Valve

Ion Pump


Interconnect diagram

Gauge Controller

Ion Pump Controller

Interconnect Diagram

Ethernet (Channel Access VLAN)

Ethernet (Field-bus VLAN)

ControlNet

LadderLogic

PLC

Flex I/O

ControlNet Interface

IOC

Ethernet Interface

Ethernet Interface

ControlNet Interface

Beamline

Gate Valve I/O

Gate Valves

TerminalServer

Analog and

Digital Signals

RS-232

Pirani + Cold Cathode Gauges

RS-232

Ion Pump


Diagnostic tanks
Diagnostic Tanks

  • Three instruments: Direct Imager, Total Energy,K-Spectrometer

  • Expect many pump/vent cycles

    • HV (~10-6)

    • Valved Turbo/scroll pump for roughing

    • Vent 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 Cathode

    • Varian V-81 Turbo-molecular Pump/Controller

    • Varian SH-110 Scroll Pump/Remote AC Contactor

  • Sequences: Pump↔Vent


Process diagram1
Process Diagram

Cold Cathode Gauge

Convection-Enhanced Pirani Gauge

(Isolation) Gate Valve

Vent Valve

Roughing Valve

Ion Pump

Turbo Pumpw/vent valve

Scroll Pumpw/fore valve


Process diagram2

Gauge Controller

Ion Pump Controller

Turbo Pump Controller

Magnetic Starter

Process Diagram

Ethernet (Channel Acces VLAN)

Ethernet (Field-bus VLAN)

ControlNet

LadderLogic

PLC

ControlNet Interface

Flex I/O

IOC

Ethernet Interface

Ethernet Interface

ControlNet Interface

Beamline

Gate Valve I/O

Valves

TerminalServer

Analog and

Digital Signals

Scroll pump control

Scroll Pumps

RS-232

Pirani + Cold Cathode Gauges

RS-232

Ion Pump

RS-232

Turbo Pumps


Gas pressure flow
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

  • Hardware

    • 2 each MKS146C, PR-4000, MKS-649, PRD-2000 pressure/flow controllers

    • 7 MKS 937A Gauge Controller ✓

      • Each 4 Convection-Enhanced Pirani +1 Cold Cathode

    • 2 each Varian 301, 701, 1001 Turbo-molecular Pump/Controller

    • 6 Varian 600DS Scroll Pump/Remote AC Contactor

    • 2 Kashiyama MU100 Screw Pump

  • Sequences: Flow↔HV↔Vent


Process diagram3
Process Diagram

Baratron

Gauge

Cold Cathode

Gauge

Convection-EnhancedPirani Gauge

(Isolation)Gate Valve

Aperture

Aperture

Pressure/Flow Valve

Roughing Valve

Roughing Valve

Screw Pump

Turbo Pumpw/vent valve

Scroll Pumpw/fore valve

x3

x2

x6


Process diagram4

Gauge Controller

Pressure Controller

Turbo Pump Controller

Magnetic Starter

Process Diagram

Ethernet (Channel Acces VLAN)

Ethernet (Field-bus VLAN)

ControlNet

LadderLogic

PLC

ControlNet Interface

Flex I/O

IOC

Ethernet Interface

Ethernet Interface

ControlNet Interface

Beamline

Gate Valve I/O

Gate Valves

TerminalServer

Analog and

Digital Signals

Scroll pump control

Scroll + Screw Pumps

RS-232

Pirani + Cold Cathode + Baratron Gauges

RS-232

Pressure/Flow Units

RS-232

Turbo Pumps


Racks power
Racks & Power

  • 40U/80″

    • 1 Triple Bay for FEE Instruments + Gas Flow

    • 1 for SOMS

  • 24U/42″ Under beamline

    • 1 for HOMS; 6 for XRT

  • Rack power distribution

    • Furman unit with 100A input; 1 in each 24U rack; 2 in 40U double rack√


Software
Software

  • EPICS √

    • 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√

  • Applications

    • PLC ladder logic does pure interlocking, using analog/digital signals

    • All commands/response from/to EPICS

    • EPICS sequencers will provide all vacuum (pump/valve) sequences; and they will control pressure set-points for gas flow






References
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



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