Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Control Module Facility Advisory Committee June 17, 2008 SLAC -

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<ul><li> Slide 1 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Control Module Facility Advisory Committee June 17, 2008 SLAC - Controls Group </li> <li> Slide 2 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Controls - design team, APS Josh Stein - Control System CAM Steve Shoaf - Lead engineer Eric Norum - RTEMS support / Consulting Bob Laird - Electronics Layout Ned Arnold - Technical supervision Sharon Farrell - Technical support Rich Voogd - Electronic Interface/Cable Design </li> <li> Slide 3 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Controls, SLAC Arturo Alarcon Ernest Williams Till Straumann James Bong </li> <li> Slide 4 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Controls The LCLS undulator line consists of a series of 33 identical undulator segments. The control and monitoring equipment for each segment will reside in a 19 rack located beneath each undulator girder. Three separate units will be housed in that rack the Motor Power/AC interlock chassis, the Undulator Control Module, and the Undulator Control Module Interface chassis. </li> <li> Slide 5 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Segment (Aisle side) BPM Quad/Corrector Translation Stage CAM Mover Electronics Rack BFW </li> <li> Slide 6 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Segment (Wall side) Vacuum chamber EIA(Raceway) </li> <li> Slide 7 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator group Short breaks Long break The entire LCLS undulator hall consists of 33 total Undulator segments broken into 11 groups of three. </li> <li> Slide 8 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Control Module Interface (UCMI) Provides a wiring interface between the Undulator Control Module (UCM), the interlock chassis, the Undulator motor power supplies and the temperature, position and control field wiring. Provides translation stage comparator circuits and calibration adjustments Contains RTD modules to acquire temperature inputs from 12 RTDs Housed in a 3U high, 12 inch deep, 19 inch rack chassis </li> <li> Slide 9 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Chassis Layout </li> <li> Slide 10 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Chassis Rear Panel </li> <li> Slide 11 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Ribbon cable connectors on back side of pcbs Rear Panel </li> <li> Slide 12 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 UCMI Temperature Monitor Uses DataForth 12 RTD modules Provides excitation for 3-Wire RTDs using matched current sources Isolation Filtering Amplifies Linearization Inputs from 3 DB15 connectors 12 RTDs Connection to UCM via SCSI II cable </li> <li> Slide 13 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Front Panel </li> <li> Slide 14 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 UCMI Motion Control Motor Interface Interface between UCM, 42 Volts Motor Power Supply and 7 Motors Five CAM movers motors Two Translation stage motors All motors fused with 10A Slow-blow fuses Use of bus bar wire for 42 VDC from Power connector to individual motor connectors and fuses. </li> <li> Slide 15 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Translation Stage Position Monitoring Translation error logic detects excessive skew Level 1 error signal relayed to UCM Level 2 error signal relayed to UCM and opens solid state relay contacts to Interlock Chassis Alignment procedure uses front panel trim pots, voltage monitor test points and LEDs. Trim pots adjust reference voltage to comparators </li> <li> Slide 16 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Beam Finder Wire (BFW) Connects 24VDC CMD Signal from UCM to BFW connector Connects 2 limit switches from BFW to UCM Connects BFW potentiometer signals to UCM Provides precision 5VDC reference signal to BFW position potentiometer Provides 24VDC to BFW </li> <li> Slide 17 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Position Monitoring Provides 5VDC precision voltage reference to 8 linear potentiometers that monitor girder position and to 5 rotary potentiometers that monitor CAM position. Connects potentiometer wipers to UCM. </li> <li> Slide 18 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Front Panel Adjustments, Indicators and Test points Alignment Offset Adjust Adjusted for Zero Volts when the Translation stages are aligned Level 1 Threshold Adjust Adjusted for the desired skew Level 2 Threshold Adjust Adjusted for the desired skew Alignment Offset +TP/-TP Test points Test points to read the alignment offset from the positive and negative reference voltages. Both should be Zero Volts when aligned. Level 1 and Level 2 Threshold Test points TDS0 and TDS1 Test points Differential Analog signals proportional to the amount of skew between the translation stages. Only one output will be non-zero, indicating the direction of the skew Ground - reference </li> <li> Slide 19 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Cont. -Front Panel Adjustments, Indicators and Test points LED Level 1 Fault LED Level 2 Fault LED Stop. Indicates E-Stop signal received from Interlock chassis LED +5V. Directly connected through resistor to 5VDC regulator LED -5V. Directly connected through resistor to -5VDC regulator LED 5V Reference. Directly connected through resistor to 5VDC precision voltage reference. LED 24V. Directly connected through resistor to 24VDC input. LED 40VA. Directly connected through resistor to 42VDC input that powers the CAM motors. LED 40VB. Directly connected through resistor to 42VDC input that powers the Translation motors. </li> <li> Slide 20 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Wiring Configuration </li> <li> Slide 21 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 EIA - Electronic Interface Assembly Purpose Provide interface for electronic cabling from undulator hardware to instrumentation rack Accommodate miscellaneous undulator wiring by means of auxiliary cabling channel Design Criteria Provide orderly cable routing from undulator hardware to instrumentation rack Provide natural grouping of specific cable types Reduce total number of cables entering instrumentation rack from undulator hardware Reduce down time associated with cabling when repairing/replacing undulator hardware User friendly system cabling installation/removal Aesthetically pleasing to overall system design </li> <li> Slide 22 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 EIA - Electronic Interface Assembly Cabling Functions Motion control - 2 translation stages &amp; 5 CAM movers Position readout - 5 rotary &amp; 8 linear potentiometers Emergency stop - 4 pushbuttons &amp; 4 translation limit switches Temperature monitoring - 12 Resistive Thermal Devices (RTDs) Beam Finder Wire (BFW) - solenoid control &amp; position readout </li> <li> Slide 23 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Segment (Wall side) EIA (Raceway) UIR (Undulator Instrumentation Rack) </li> <li> Slide 24 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 EIA - Electronic Interface Assembly </li> <li> Slide 25 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Hardware Cabling Design Assessing Cabling Requirements Undulator hardware identification establish nomenclature Determination of routing (thru EIA or direct) to rack Introduction of emergency stop capability (motor power) Determining EIA &amp; Undulator Instrumentation Rack (UIR) location Specifications of Connector &amp; Cable Type Choosing connector types Quality &amp; ease of installation/removal Connector type varies per function requirements Choosing cable types Selected for function (power, signal, control, etc.) Specifying custom cable where applicable </li> <li> Slide 26 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Hardware Cabling Design Planning for Cable Routing Determination of appropriate routing along girder support system Routing to junction boxes A &amp; B Motor cables routed directly to Undulator Instrumentation Rack (UIR) Determination of individual cable lengths Cables Types &amp; Quantities (49 cables total / undulator) 7 motor power (2 Translation &amp; 5 CAM movers) 4 emergency stop pushbutton 2 translation limit switch 5 rotary potentiometer 8 linear potentiometer 12 temperature (RTDs) 2 Beam Finder Wire (BFW) 9 Instrumentation Rack </li> <li> Slide 27 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 SUT Section Top View </li> <li> Slide 28 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Typical Cable Drawing </li> <li> Slide 29 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Hardware System Wiring Overall Wiring Plan Hardware to electronic interface assembly Hardware to instrumentation rack cabling EIA to instrumentation rack cabling Electronic Interface Assembly Internal Wiring All cables route thru EIA with exception of motor cables Reduction of cables to instrumentation rack Emergency stop - from 6 to 1 Rotary potentiometers - from 5 to 2 Linear potentiometers - from 8 to 2 RTDs - from 12 to 3 Beam Finder Wire (BFW) - from 2 to 1 Reduced total quantity by 24 / undulator </li> <li> Slide 30 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Hardware System Wiring Junction Box A &amp; B Cabling Hardware cable entry to junction boxes 18 cables entering junction box B 15 cables entering junction box A EIA to Instrumentation Rack Cables 1 emergency stop 2 rotary potentiometers 2 linear potentiometers 3 temperature (RTDs) 1 Beam Finder Wire (BFW) </li> <li> Slide 31 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Electronic Interface Assembly/Junction Box A </li> <li> Slide 32 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Electronic Interface Assembly/Junction Box B </li> <li> Slide 33 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Motor Power/Interrupt Chassis Design Chassis Functions Provide motor power for translation stages &amp; CAM movers Provide power for Undulator Control Module Interface (UCMI) Emergency motor power interrupt / status indication Interacts with UCMI - status &amp; control Power Supply Selection &amp; Power Distribution 2 42V DC / 20A power supplies for 7 motors 1 24V DC / 1.2A power supply for UCMI chassis Emergency Stop Circuitry 4 emergency stop pushbuttons (key reset) on girder support 4 translation limit switches - in / out (upstream &amp; downstream) Translation stage skew signal - level 2 fault from UCMI </li> <li> Slide 34 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Motor Power/Interrupt Chassis Design Interfacing With The UCMI Powers UCMI chassis with 24V DC Provides 42V DC to UCMI for powering 7 motors Receives fault status (normally closed contact) from UCMI Sends E-Stop status (motor power normal / interrupted) to UCMI Status Indicators / Test Points Front panel LEDs to indicate status 1 24V DC supply 2 42V DC supplies LEDs to indicate status (normal / fault) of motor power Front panel test points to monitor all 3 power supplies </li> <li> Slide 35 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Smart Motor / Power Supply Information Smart Motor Specifications Animatics Model SM2320D - PLS Integrates a motion controller, amplifier, and feedback encoder in the back of a high quality brushless DC servo motor Animatics Motor Ratings Continuous Torque - T c 38 oz - in Peak Torque - T p 90 oz - in Torque Constant - K t 8.92 oz - in/A No Load Speed7820 rpm Voltage Constant6.6 V / K rpm Peak Current I p = T p / K t I p = (90 oz - in) / (8.92 oz - in/A) I p = 10.09 A Continuous TorqueI c = (38 oz - in) / (8.92 oz - in/A) I c = 4.26 A </li> <li> Slide 36 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Smart Motor / Power Supply Information Power Supply Requirements Linear unregulated DC voltage 22 to 48 Volts DC Animatics model PS42V20AF11042 Volts DC @ 20 Amps Only one supply required to operate all 7 Smart Motors Shunt recommended for back EMF protection 12.5 OHM 100 Watt shunt (2) 1 for each power supply 24 Volt DC linear regulated power supply for UCMI power PowerOne HB24-1.2-A24 Volt DC @ 1.2 Amps </li> <li> Slide 37 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Circuit - Motor Power/Interrupt Chassis </li> <li> Slide 38 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Motor Power / Interrupt Chassis </li> <li> Slide 39 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Motor Power/AC Interrupt Chassis </li> <li> Slide 40 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 Undulator Control Module (UCM) - Functionality Overview Motion control of five undulator CAM movers and two translation stages Position readback of various potentiometers distributed around the undulator girder, including interlocking logic of the translation stages Temperature monitoring of RTDs distributed around the undulator Control of the Beam Finder Wire diagnostic including position readback </li> <li> Slide 41 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu June 17, 2008 UCM - Requirements Limitation of motor positioning soft limits imposed by software Limit switches to disable motor movement Limit switches to remove motor drive power Emergency stop signal from the AC interrupt/interlock chassis Translation stage control and skew interlocks Control of two independent translation stages Interlock function to prevent unintentional skew of the strongback Internal diagnostics to monitor the operation of the undulator controls </li> <li> Slide 42 </li> <li> Arturo Alarcon FAC, Undulator Controlsalarcon@slac.stanford.edu...</li></ul>

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