The Implementation Strategy
Proposed SLAC Controls UpgradeDecember 1, 2010
Ray Larsen
Controls Upgrade Implementation 2
Outline
1. Existing System2. MTCA Module Development 3. Single Station Upgrade Demo Plan4. Production & Test Plan5. Steps to Installation & Switchover (TH)
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Existing System• Every RF station has 2-bay rack for controls
– 8 Stations per each of 30 Sectors– Includes 6-8 RF Stations for each injector– New upgrade RF plus accelerator controls can fit in
single rack
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Klystron Gallery Layout
Controls Upgrade Implementation
KEEP OUT AREA FOR KLYSTRON REPLACEMENT
Modulator
KlystronPenetration
Fiat Racks
Possible Obstructions
Sub-Booster (22")Arc Flash Boundary (12")
Storage (6-42")Transformers (~36")
Other Racks
48"
72"
SupportPost
14"
48"
24"
24"POSSIBLE NEW DOUBLE BAY RACK LOCATION
48"
POSSIBLE NEWDOUBLE BAY RACK
LOCATION
28"
40"
28"Possible Obstructions:
Arc Flash BoundaryStorage
TransformersOther Racks
Keep Out Area PFN Tuning
Keep Out AreaT20 Replacement(Can be shifted 6ft to the right)
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Short cables top of penetration would need elongation to new rack
TANK
MAGNET
SLED
RACKS
WG & Cable Penetrationto Tunnel
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PAD ChassisMeasures RF Phase and Amplitude
MKSU ChassisInterlock and Control for Klystron SLED Support Systems
PIOP CAMAC ModuleControls IPA, PAD, and MKSU. Interface to control system
Existing Linac Klystron Station RF Control, Monitoring, and Interlocking System
New system will combine the PAD, IPA, and part of the PIOP into the RF Control System
IPA ChassisControls RF Phase and Amplitude
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Existing Controls Racks
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PDU TimingPIOPs (4)
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Existing Rack Issue• Racks are sub-standard in meeting code, cooling
and filtering protection– Ideally would install modern environmentally controlled
closed racks– Not in budget & some stations lack space
• Proposed work-around – Refurbish present rack to bring ~up to code, plus add
power for local solenoid PS plan (new)– Insert secondary enclosure inside rack with crate
cooling, sealed from dirty air, w/LCW air-water temp control
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2. MTCA Module Development
• The following show the MTCA development strategy for in-house RTM design.
• We are procuring generic COTS AMCs each of which will support a number of applications via RTMs
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MTCA Engineering Reference Design
AMC
RTMHOT SWAP IPMI
EJECTION LOGIC SERIAL Gb BACKPLANE
FPGA
DC-DC CONVERT
4 DUAL DIFFERENTIAL SHLD’D PAIRS
12V PWR, GND, JTAG, IPMI
56 DUAL DIFFERENTIAL SHLD’D SIGNAL PAIRS HOT SWAP, PWR IPMI
EJECTION LOGIC
RE
AR
I/O
IPMI MMC CONTROLLER
Reference Design complete w/ supporting FW-SW environment enables engineers to focus on payload design w/ power, IPMI basic infrastructure standardized
Double-wide plus RTM provides excellent analog space, ground noise control, crosstalk
AMC space fully backward compatible with industry single-wide designs
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Adapting Controls Subsystems• Port existing front end interfaces onto RTMs
• 4 & 10 Ch Fast ADCs w/DAC RTM adapters:1. Stripline BPMs (2 types)2. Toroids (2 types, Linac & Beam Containment), Profile
Monitor Gated ADC (Same as above)3. RF Feedback
• 3-Industry Pack RTM Adapters: 4. Profile Monitor Beam Length (BLEN)5. Vacuum gauge controller interface6. Vac-ion pump controller interface7. Wire scanner movers (Hytek)
• PMC Card AMC Adapter8. Fast Frame grabber for Profile Monitor
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Beamline BPMs, Toroids, Gated ADCs
RTM 1STRIPLINE BPM
(2 TYPES) SIGNAL CONDITIONING,
FILTERING & CALIBRATION
AMC 1FAST ADC
4 CH 16 BIT 119 MSPS(180 MSPS MAX)
RTM 2TOROID (2 TYPES)
SIGNAL CONDITIONING & CALIBRATION
RTM 2GATED ADC SIGNAL
CONDITIONING (GADC)
Strategy: Encourage
Industry to provide key generic complex AMC modules
Develop 2 or more sources
Encourage multiple lab- supported specifications
(Struck, Vadatech,Libera)
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LLRF System, Feedback Apps
AMC 2FAST ADC
10 CH 16 BIT 119 MSPS2 CH DAC 238 MSPS
RF FREQUENCY GENERATIONLOCAL OSCILLATOR (LO)
SAMPLING CLOCKS8 CH DOWNCONVERTER
2856 MHZ REF IN
I/O CNTRLRTM-325 MHZ IF SIGNAL PASSTHROUGH
DAC OUTPUT TO RF AMP
IF SIGS
DAC OUT
RTM-3GENERIC FAST
SIGNAL CONDITIONING UP TO 10 CH ANALOG IN, 2 CH DAC OUT
(Struck,VadatechLibera)
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Beamline Instruments via IP Adapter
RTM 4BLEN BROFILE MONITOR
GENERIC 3 IP 1/0 ADAPTER, SCSI PORT,
IPMI PASSTHOUGH
AMC 33-INDUSTRY PACK (IP)
ADAPTER FOR PHYSICS BACKPLANE
RTM 4VACUUM GUAGE
READOUT, REMOTE WAKEUP
RTM 4VACI-ION PUMP CONTROLLER
INTERFACE
RTM 4WIRE SCANNER MOVERS
HYTEK IP DESIGNPORT FW, SW FROM
XSTG DESIGN
1-3 INDUSTRY
PACKS
(TEWS, Vadatech)
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High BW Frame Grabber PMC Adapter
RTM 5SIMPLE INTERFACE
PASSTHOUGH FOR PMCE.G.PROFILE MONITOR
HIGH DATA BW FAST FRAME GRABBER
AMC 4PMC ADAPTER
FIBER OPTIC MULTI- GIGABIT LINKS
STANDARD PMC BOARD
GENERIC ADAPTER E.G. VADATECH, TEWS
(TEWS, Vadatech)
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3. Single Station Upgrade Demo Plan
• Proposed staging plan (Station 28-2):– Integrate Controls and RF subsystems separately
on identical MTCA platforms– Controls Infrastructure Team supports both with
test hardware, firmware, IPMI, low and high level software (in process)
– Subsystems integrated, lab-tested separately– Temporary air-water cooled rack installed in 28-2– Merge tested subsystems in 28-2– Test each offline, then together online with beam
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Single Station Components (Typ.)
• Station Control Functions– Klystron-Modulator Interface (MKSUII)
• Interlocks & monitoring• Solid state sub booster monitoring• Local displays & controls
– Controls & Monitoring (MTCA)• Status of RF Controller via ADC-DAC RTM• Heater & Solenoid power supplies - SLED Tuners• MK Interlocks – Vacuum – Temperatures• BPMs – wire scanners – profile monitors• Network interface to/from modulators
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Test Station BD – RF & Accelerator
Controls Upgrade Implementation
40ft ACCEL.SECTION INSTRUMENTS
& CNTRLS
SYNC CLOCKS & LO GENERATION
MAIN DRIVE LINE
BPMsToroids
Wire ScanProfile Mon.
VacuumPower Supplies
BCSTemperature
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Station Crate Layout (Typ.)
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PO
WE
R U
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1- R
ED
UN
DA
NT
MC
H H
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CO
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ER
& M
GR
TIM
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MO
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FPG
A IN
TER
LOC
K S
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FAS
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DC
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0-2
CH
BP
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TOR
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BP
M2
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PR
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WIR
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MO
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H H
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CO
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& M
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PO
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1
PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)
PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)
text
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121 2 3 4 5 6 7 9 118 10
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InfrastructurePwr, MCH, IOC,
Timing
RFFdbk
Controls Modules (Typ.) Redundant MCH, Pwr Options
SPA
RE
SLO
T
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Side View Crate, AMC, RTM
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text
FAN TRAY-HOTSWAP
FRONT END MODULE
ADVANCED MEZZANINE CARD (AMC)
INPUT/OUTPUT SIGNAL CONDITIONING
REAR TRANSITION MODULE (RTM)
I/O
I/O
BP CONN
BACKPLANE
AIR IN
AIR OUT
FAN TRAY-HOT SWAP
USE
R D
EFIN
ED I/
O C
ON
NEC
TOR
S
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Note – All I/O in Rear; both AMC, RTM Hot Swappable
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MTCA 12-Slot Shelf & Modules
12 Slot Crate & Front-Rear Fan Tray (Schroff)
6 Slot Cratew/ AMC & RTM(Schroff)
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Upgraded Station Rack Profile
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SOLENOID POWER SUPPLY
RF GENERATION & DOWNMIX
MKSUII
POW
ER U
NIT
1- R
ED
UN
DAN
T
MC
H H
UB
CO
NTR
OLL
ER
& M
GR
TIM
ING
MO
DU
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FPG
A IN
TER
LOC
K S
UM
FAS
T AD
C-D
AC
10-
2 C
H
BPM
1
TOR
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BPM
2
IOC
PR
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OR
PRO
FILE
FR
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RA
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VAC
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PU
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VAC
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EN
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INTE
RFA
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WIR
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CA
NN
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OVE
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MC
H H
UB
CO
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OLL
ER
& M
GR
POW
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1
PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)
PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)
text
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text
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121 2 3 4 5 6 7 9 118 10
MTCA CONTROLS
AC POWER PANEL
HEAT EXCHANGER
CROSS-CONNECT
RF IN-OUT
CONTROLS IN-OUT
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In-Rack Crate Enclosure
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SOLENOID POWER SUPPLY
RF GENERATION & DOWNMIX
MKSUII
PO
WE
R U
NIT
1- R
ED
UN
DA
NT
MC
H H
UB
CO
NTR
OLL
ER
& M
GR
TIM
ING
MO
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FPG
A IN
TER
LOC
K S
UM
FAS
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DC
-DA
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0-2
CH
BP
M 1
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BP
M2
IOC
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WIR
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MC
H H
UB
CO
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OLL
ER
& M
GR
PO
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1
PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)
PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)
text
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PENETRATION
text
FAN TRAY-HOTSWAP
FRONT END MODULE
ADVANCED MEZZANINE CARD (AMC)
INPUT/OUTPUT SIGNAL CONDITIONING
REAR TRANSITION MODULE (RTM)
I/O
I/O
BP CONN
BACK
PLANE
AIR IN
AIR OUT
FAN TRAY-HOT SWAP
USER
DEF
INED
I/O
CO
NN
ECTO
RS
RF CABLES TO/FROM TRAYS
CABLES TO/FROM TUNNEL
REAR I/O CABLES TO/FROM RTM’S
WATER COOLED ENCLOSURE
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4. Production & Test Plan• Procurement Controls
– All MTCA components except RTMs purchased from vendors
– Arrive tested including basic SW, FW– RTMs designed in house relatively simple;
vendors will be interested to bid on providing tested units.
– Otherwise contract fabrication & test in-house – Rack enclosure with heat exchanger will be
contracted to a chassis manufacturer offering the service
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Generic Application AMC’s• Three AMC’s with RTMs serve all RF needs:
1. Fast ADC DAC AMC module for RF phase, amplitude control and feedback
2. General Analog-Digital Industry Pack (IP) carrier AMC to serve all miscellaneous monitoring and controls
3. PMC Adapter to easily port existing designs in LCLSI• Item 1 delivered & in test; item 2 quote in hand for order;
item 3 exists and needs porting to RTM version• Standards Goal: Procure key modules from at least
2 vendors
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Struck SIS 8300 RF Digitizer
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RTM Connector
AMC Connector
10 Ch 16 bit 125 MSPS2 Ch 16 bit DAC outputVirtex 5 FPGA
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Timing Module – Stockholm U.
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Timing AMC (University of Stockholm)• Fiber optic links w/ drift compensation• ps stability• AMC module is receiver and transmitter• Clock, trigger and event distribution
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Production 2• RF Chassis (2)
– 2 separate chassis are being designed, one with RF circuitry and water-cooled heat sink, the other the MKSUII protection chassis
– These are custom units deemed to be not suitable for MTCA packaging partly due to special constraints
– Fabrication for quantities will be less amenable to outside fabrication and testing except for ADC-DAC which is MTCA AMC-RTM.
– Will seek out vendors who can provide integrated service and back up with in-house shop and production testing.
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Production 3• Pre-test and field integration
– Since installing into existing racks, no normal luxury of pre-loading racks in shop, testing before field installation
– Will increase Davis-Bacon costs labor in field– All field cable retrofitting done by skilled contractors or
SLAC personnel (bad contractor performance on controls cables is a given)
– All chassis units fully pre-tested, calibrated before install– Purchased modules and RTMs checked in crate and
crate installed – RTM cables prefab & tested before field install– Following slide shows production install flow
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CONTROLS & RF CONVERSION PLAN 12-1-10G
ALL
ERY
INFR
AST
RU
CTU
RE
POW
ER
CO
NVE
RSI
ON
RF
SUB
SYST
EMC
ON
TRO
LS
UPGRADE RACKS IN SITU OR PROCURE
NEW
PROCURE ALL MODULAR COTS COMPONENTS
PROCURE ALL MODULAR COTS COMPONENTS
UPGRADE MODULATOR INTERFACE
FABRICATE ALL IN-HOUSE
COMPONENTS (CONTRACT)
FABRICATE ALL IN-HOUSE
COMPONENTS (CONTRACT)
EEIP RACKSUPGRADE
ENCLOSURELCW HEAT
XCHGR
PREPARE MODULATOR
INTERFACE(OLD, NEW)
PREPARE SOLENOID PS INTERFACE
LOAD RACKS IN SITU(IF XSTG)INSTALL (IF
NEW)
LOAD CRATES IN ASSY SHOP
LOAD RACKS IN PCD ASSY
SHOP(IF NEW)
CONVERT CABLE
CONNECTORS
CONVERT RF INTERLOCK
CABLE CONNECTORS
ATTACH STATION CABLES
COMMISSION STATIONINSTALL TIMING INSTALL ENET
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Production & Installation Summary• Production and installation scenarios can be highly
flexible due to modular nature of accelerator and small chassis and modular assemblies involved– Rack issues in gallery still need work (with PCD) toward
optimum solution – cannot grandfather sub-standard units forever
– Developing 2 or more vendors for key infrastructure and controls applications modules
• In next section T. Himel discusses strategies for changeover within constraints of running LCLS and FACET programs
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5. Steps to Installation & Switchover
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- Contributed by T. Himel
Controls Upgrade Implementation
Steps to switchover
• First, get all multi-sector or multi-system control of FACET handled by new LCLS style applications (mainly EDM and Matlab)– This was mostly the case for LCLS before our
upgrade started. A few had to be moved from old to new. An effort will be required to extend these to FACET, but much smaller than originally doing it for LCLS. The physicists and OPS are used to this and will want FACET to head in that direction anyway.
– There are only two ways these applications have to access SLC data: SLCCAS (SLC Channel Access Server) and AIDA.
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Controls Upgrade Implementation
Installation during FACET era
• FACET will be running 4 months a year for the next 5 years using sectors 0-20 and the damping rings.
• The exact schedule is unknown, but worst case is two 2-month runs each year. (Linac startup time is so long, I cannot imagine more shorter runs.)
• These downtimes are too short to install the full upgrade during a single downtime.
• Hence we need a way to do partial installs and run FACET with mixture of two control systems.
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Controls Upgrade Implementation
Installation during FACET era
• We are doing something similar with the phase I upgrade in sectors 21-30 right now.
• It is somewhat easier than what we will be doing for FACET because we only have to move one cable (the CAMAC cable) per sector to switch between old and new control system. It is somewhat harder because LCLS is much less tolerant of downtime than FACET.
• We are, however, set up to be able to run LCLS with sectors split between old and new control systems. We will use a similar method for FACET.
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Controls Upgrade Implementation
Steps to switchover
• Second, setup a PVgateway to translate PV requests heading towards SLCCAS.– SLCCAS provides read-only access to items
in the SLC DB by responding to broadcasts for PVs.
– These will be channeled though a PVgateway whose setup can be easily changed to either get the data from SLCCAS or to provide nothing so that the data will instead come from newly installed µTCA IOCs.
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Controls Upgrade Implementation
Steps to switchover
• Third, setup AIDA so it can read and write the data it handles from either the new or old control system. (This has been done for klystron and timing control for Phase I)– A small quick DB change is then used to tell
AIDA to change which control system it uses to service requests it receives.
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Controls Upgrade Implementation
Steps to switchover
• Next, during a long downtime we install new hardware for whatever sectors and systems we have time and budget to do.
• We provide EDM screens for detailed control of the new devices.
• We modify the PVgateway and AIDA setups to indicate the new hardware should be used.
• Checkout as much as we can before FACET turn-on.• Schedule check-out time during the FACET turn-on• Repeat above steps for other
systems/sectors/downtimes until done.
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END OF SLIDES
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