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XTOD Vacuum Controls Final Design Review

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

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  1. XTOD Vacuum ControlsFinal Design Review Steve Lewis/Keith Kishiyama 13 March 2008

  2. 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

  3. 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: √

  4. 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

  5. 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

  6. 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

  7. Block Diagrams

  8. 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

  9. 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

  10. ‘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

  11. Process Diagram Cold Cathode Gauge Convection-Enhanced Pirani Gauge (Isolation) Gate Valve Manual Cart Valve Ion Pump

  12. 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

  13. 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

  14. 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

  15. 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

  16. 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

  17. 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

  18. 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

  19. 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√

  20. 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

  21. Photos of Ongoing Fabrication at LLNL

  22. Prototype of Flex-I/O Wiring

  23. Partly Loaded Main FEE Rack(front)

  24. Partly Loaded Main FEE Rack (rear)

  25. 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

  26. Complete book of wiring diagrams available

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