The Implementation Strategy

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)

Controls Upgrade Implementation 12-01-10


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


Controls Upgrade Implementation 4Controls Upgrade Implementation 12/01/10

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


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


Existing Controls Racks

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Controls Upgrade Implementation 7Controls Upgrade Implementation

PDU TimingPIOPs (4)

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Controls Upgrade Implementation 8Controls Upgrade Implementation 12-01-10


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



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


Controls Upgrade Implementation Controls Upgrade Implementation 12/01/10

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


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


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)


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)


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)


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)


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



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



Test Station BD – RF & Accelerator


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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1- R

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FPG

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TER

LOC

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FAS

T A

DC

-DA

C 1

0-2

CH

BP

M 1

TOR

OID

BP

M2

IOC

PR

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PR

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PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)

PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)

text

text

text

text

text

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


Side View Crate, AMC, RTM


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


MTCA 12-Slot Shelf & Modules

12 Slot Crate & Front-Rear Fan Tray (Schroff)

6 Slot Cratew/ AMC & RTM(Schroff)

22


Upgraded Station Rack Profile


SOLENOID POWER SUPPLY

RF GENERATION & DOWNMIX

MKSUII

POW

ER U

NIT

1- R

ED

UN

DAN

T

MC

H H

UB

CO

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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

OID

BPM

2

IOC

PR

OC

ESS

OR

PRO

FILE

FR

AM

E G

RA

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VAC

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PU

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VAC

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AUG

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OVE

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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


In-Rack Crate Enclosure


SOLENOID POWER SUPPLY

RF GENERATION & DOWNMIX

MKSUII

PO

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1- R

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MC

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A IN

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FAS

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0-2

CH

BP

M 1

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BP

M2

IOC

PR

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121 2 3 4 5 6 7 9 118 10

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


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



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



Struck SIS 8300 RF Digitizer


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.


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.



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


Controls Upgrade Implementation 31Controls Upgrade Implementation 12/01/10 Controls Upgrade Implementation

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



5. Steps to Installation & Switchover


- Contributed by T. Himel


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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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.

35


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.

36


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.

37


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.

38


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.

39


END OF SLIDES


Documents

The Implementation Strategy