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Undulator Control Module

Undulator Control Module. Facility Advisory Committee June 17, 2008 SLAC - Controls Group. Undulator Controls - design team, APS. Josh Stein - Control System CAM Steve Shoaf - Lead engineer Eric Norum - RTEMS support / Consulting Bob Laird - Electronics Layout

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Undulator Control Module

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  1. Undulator Control Module Facility Advisory Committee June 17, 2008 SLAC - Controls Group

  2. 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

  3. Undulator Controls, SLAC • Arturo Alarcon • Ernest Williams • Till Straumann • James Bong

  4. 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.

  5. BFW Undulator Segment (Aisle side) Quad/Corrector BPM Translation Stage Electronics Rack CAM Mover

  6. Undulator Segment (Wall side) EIA(Raceway) Vacuum chamber

  7. Undulator group • The entire LCLS undulator hall consists of 33 total Undulator segments broken into 11 groups of three. Short breaks Long break

  8. 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 RTD’s • Housed in a 3U high, 12 inch deep, 19 inch rack chassis

  9. Chassis Layout

  10. Chassis – Rear Panel

  11. Rear Panel Ribbon cable connectors on back side of pcb’s

  12. UCMI Temperature Monitor • Uses DataForth 12 RTD modules • Provides excitation for 3-Wire RTD’s using matched current sources • Isolation • Filtering • Amplifies • Linearization • Inputs from 3 DB15 connectors • 12 RTD’s Connection to UCM via SCSI II cable

  13. Front Panel

  14. 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.

  15. 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 LED’s. • Trim pots adjust reference voltage to comparators

  16. 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

  17. 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.

  18. 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

  19. 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.

  20. Undulator Wiring Configuration

  21. 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

  22. EIA - Electronic Interface Assembly • Cabling Functions • Motion control - 2 translation stages & 5 CAM movers • Position readout - 5 rotary & 8 linear potentiometers • Emergency stop - 4 pushbuttons & 4 translation limit switches • Temperature monitoring - 12 Resistive Thermal Devices (RTD’s) • Beam Finder Wire (BFW) - solenoid control & position readout

  23. Undulator Segment (Wall side) EIA (Raceway) UIR (Undulator Instrumentation Rack)

  24. EIA - Electronic Interface Assembly

  25. 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 & Undulator Instrumentation Rack (UIR) location • Specifications of Connector & Cable Type • Choosing connector types • Quality & 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

  26. Undulator Hardware Cabling Design • Planning for Cable Routing • Determination of appropriate routing along girder support system • Routing to junction boxes ‘A’ & ‘B’ • Motor cables routed directly to Undulator Instrumentation Rack (UIR) • Determination of individual cable lengths • Cables Types & Quantities (49 cables total / undulator) • 7 motor power (2 Translation & 5 CAM movers) • 4 emergency stop pushbutton • 2 translation limit switch • 5 rotary potentiometer • 8 linear potentiometer • 12 temperature (RTD’s) • 2 Beam Finder Wire (BFW) • 9 Instrumentation Rack

  27. SUT Section Top View

  28. Typical Cable Drawing

  29. 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 • RTD’s - from 12 to 3 • Beam Finder Wire (BFW) - from 2 to 1 • Reduced total quantity by 24 / undulator

  30. Undulator Hardware System Wiring • Junction Box ‘A’ & ‘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 (RTD’s) • 1 Beam Finder Wire (BFW)

  31. Electronic Interface Assembly/Junction Box ‘A’

  32. Electronic Interface Assembly/Junction Box ‘B’

  33. Motor Power/Interrupt Chassis Design • Chassis Functions • Provide motor power for translation stages & CAM movers • Provide power for Undulator Control Module Interface (UCMI) • Emergency motor power interrupt / status indication • Interacts with UCMI - status & control • Power Supply Selection & 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 & downstream) • Translation stage skew signal - level 2 fault from UCMI

  34. 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 LED’s to indicate status • 1 24V DC supply • 2 42V DC supplies • LED’s to indicate status (normal / fault) of motor power • Front panel test points to monitor all 3 power supplies

  35. 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 - Tc 38 oz - in • Peak Torque - Tp 90 oz - in • Torque Constant - Kt 8.92 oz - in/A • No Load Speed 7820 rpm • Voltage Constant 6.6 V / K rpm • Peak Current Ip = Tp / Kt Ip = (90 oz - in) / (8.92 oz - in/A) Ip = 10.09 A • Continuous Torque Ic = (38 oz - in) / (8.92 oz - in/A) Ic = 4.26 A

  36. Smart Motor / Power Supply Information • Power Supply Requirements • Linear unregulated DC voltage 22 to 48 Volts DC • Animatics model PS42V20AF110 42 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-A 24 Volt DC @ 1.2 Amps

  37. Circuit - Motor Power/Interrupt Chassis

  38. Motor Power / Interrupt Chassis

  39. Motor Power/AC Interrupt Chassis

  40. 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

  41. 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

  42. UCM - Hardware Design • Commercially available VME hardware for IOC • Motorola processor • Industry Pack Modules (ADC, RS-232, Digital I/O) • Responsible for • motion control • position readbacks • translation stage position monitoring • temperature monitoring • Beam Finder Wire control and position readback • Undulator Control Module Interface (UCMI ) Chassis • Field wiring connection interface • Connects to IOC via high density 50 pin SCSI-II cables • Motor Power/AC Interrupt Chassis • Terminates motor power for emergency stop buttons or translation stage skew

  43. UCM - Motion Control • LCLS Undulator Support/Mover System Engineering Specification (#1.4-112) • CAM motion details • Translation stage motion details • APS EPICS motor record device support • Animatics SmartMotors • UCMI Chassis • Field wiring interfaces directly to all motors, not through junction box • Houses circuit board to distribute power and serial I/O to each motor • Serial I/O and motor power via hybrid cable • Houses translation stage skew monitor circuit

  44. UCM - Position Readbacks • Eight linear potentiometers for girder position monitoring • Manufacturer: novotechnik • Model: TR10 • Animatics Smart Motor internal encoder readback for CAM position • Five Rotary potentiometers for CAM position monitoring • Manufacturer: novotechnik • Model: P2200 • Two linear potentiometers for translation stage position monitoring • Manufacturer: novotechnik • Model: TRS100 • Two undulator translation limit switches • Manufacturer : Micro-Switch (Honeywell) • Model: 11SM1

  45. UCM - Girder Position Monitoring • Eight linear potentiometers monitoring girder position • Independent position feedback of the girder at each location • 1kΩ potentiometer • Independent linearity of ± 0.25% • Independent repeatability of 10µm • Precision voltage source used for the potentiometers for accurate measurements • Analog Devices AD586 (5V ± 2.5mV) • Long term power supply drift compensation • Dedicated ADC channel to monitor precision power supply output • Loopback configuration for motion control is possible • Not currently implemented, SUT results showed single motion always in spec. • Characterization with 16-bit ADC • Need 13 bits of resolution to obtain ±2 micron readback over 10 mm range • Characterization will be done during Long Term Test (LTT)

  46. UCM - CAM Position Monitoring • Rotary potentiometers monitor CAM positions (indirectly monitor quad position) • 5 kΩ potentiometer • 360° of mechanical travel • 345° of electrical travel • Independent linearity of ± 0.1% • Independent repeatability of less than 0.01 degrees • Transformation matrix used to calculate the center of the downstream quad • Precision voltage source used for potentiometers for accurate measurements • Long term power supply drift compensation • Dedicated ADC channel to monitor precision power supply output • Characterization with 16-bit ADC • Need 13 bits of resolution to obtain ±0.05° readback over 360° • 2µm of quad linear motion ~0.05° of CAM motion • Characterization results have yielded resolutions of 0.01°

  47. UCM - Translation Stage Position Monitoring • Two linear potentiometers monitoring translation stage positions • Independent position feedback of the two translation stages • 5kΩ potentiometer • Independent linearity of ± 0.075% • Independent repeatability of 10µm • Precision voltage source used for the potentiometers for accurate measurements • Long term power supply drift compensation • Dedicated ADC channel to monitor precision power supply output • Characterization with 16-bit ADC • Need 13 bits of resolution to obtain ±15 micron readback over 100 mm range • Characterization will be done during Long Term Test (LTT) • Two undulator translation limit switches • Connected to the Animatics Smart Motor limit switch inputs • Two additional limits wired directly to the AC Interrupt Chassis

  48. UCM - Translation Stage Skew Monitoring • Translation stage comparator circuit inside the UCMI Chassis • Two levels of transverse skew interlock intervention • Level 1 threshold, when motion begins to get outside of acceptable alignment • UCM enters alarm state which requires operator intervention • One motor individually moved to match other motors position • Level 2 threshold, if the magnitude of the skew continues • AC interrupt chassis is tripped, cuts power to all motors • UCM enters alarm state which requires engineering intervention • Calibrated alignment of stage positions • Level 1 and Level 2 have a single alignment adjustment • Level 1 and Level 2 have independent threshold adjustments • Level 2 violation will require a tunnel access to visually inspect the problem • Motion interlock clear button on Motor Power/AC Interrupt Chassis • Allows movement of translation stages to clear the fault

  49. UCM - Temperature Monitoring • Twelve RTD sensors positioned on girder assembly • Vendor: Omega • Model: RTD-830 surface mount • UCMI Chassis • Field wiring interface for all RTD’s • Interfaced to Dataforth RTD modules inside chassis • RTD excitation voltage • Isolates, filters, amplifies and linearizes a single channel of temperature input

  50. UCM - Temperature Monitoring • Ambient temperature monitoring around girder • 3 wire RTD’s • Longer wire operating lengths (not an issue with this installation) • 2 wire configuration can be up to 100m, 3 wire configuration can be up to 600m • Minimizes lead wire resistance effects • Platinum element • High accuracy (a typical 100 ohm sensor is nominally 0.385 ohm/°C) • Low drift • Fast response (extremely thin film) • Linear resistance-temperature relationship • Wide temperature operating range (-60 to 260 °C) • Characterization with 16-bit ADC • Need 13 bits of resolution to obtain ±0.05 °C readback over 320 °C range • Characterizationwill be done during Long Term Test (LTT)

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