Undulator Control Module
Facility Advisory Committee Review,
October 30th 2007
UCM - Design Team
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Josh Stein - Control System CAM
Steve Shoaf - Lead Engineer
Eric Norum RTEMS Support/Consulting
Bob Laird - Electronics Layout
Rich Voogd - Cable Design
Ned Arnold - Technical Supervision
Sharon Farrell - Technical Support
Introduction
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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.
Undulator Segment (Aisle side)
BFW
Translation Stages
CAM Movers
Electronics Rack
Undulator Control Module (UCM) - Functionality Overview
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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 for skew motion protection
Temperature monitoring of RTDs distributed around the undulator
Control of the Beam Finder Wire diagnostic including position readback
UCM - Controls Hardware Evolution
V1 - “EPICS Brick” PC-104 IOC
V2 - “Blade IOC” PC-104
V3 - Traditional VME IOC
UCM - Hardware Design
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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
UCM - Undulator Control Module Interface (UCMI)
UCM - Position Monitoring
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Eight linear potentiometers monitoring girder position
– Independent linearity of ± 0.25%, and repeatability of 10µm
Rotary potentiometers monitor CAM positions (indirectly monitor quad position)
– 360° of mechanical travel, 345° of electrical travel
– Independent linearity of ± 0.1%, repeatability of less than 0.01 degrees
– Transformation matrix used to calculate the center of the downstream quad
• Need 13 bits of resolution to obtain ±0.05° readback over 360°
• 2µm of quad linear motion ~0.05° of CAM motion
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
Loopback configuration for motion control is possible
– Not currently implemented, SUT results showed single motion always in spec.
UCM - CAM Position Monitoring
UCM - Translation Stage Position Monitoring
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Two linear potentiometers independently monitoring translation stage position
– Independent linearity of ± 0.075%, repeatability of 10µm
– Precision voltage source used for accurate measurements
– Long term power supply drift compensation
Translation stage skew interlock circuit inside the UCMI Chassis
• Level I 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 II threshold, if the magnitude of the skew continues
– AC interrupt chassis is tripped, cuts power to all motors
– Calibrated alignment of stage positions
• Level I/Level II have a single alignment adjustment, independent threshold
adjustments
Level II violation will require a tunnel access to visually inspect the problem
– Motion interlock override button on UCMI Chassis
UCM - Temperature Monitoring
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3 wire platinum element RTD’s
– Interfaced to Dataforth RTD modules inside UCMI chassis
• Isolates, filters, amplifies and linearizes a single channel of temperature input
– 3 wire configuration minimizes lead wire resistance effects
– 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)
UCM - BFW Controls
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BFW Hardware Controls
– A 24V dc signal activates BFW solenoid
– Two limit switches for IN/OUT position readback
– Linear potentiometer used to verify “IN” position accuracy
UCM - Hardware Platform
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VME IOC Hardware
– Hybricon Crate (SLAC specifications)
• Remote console access
• Remote monitoring of voltage and fan
• Remote reboot and power cycling
– Motorola mvme3100 Processor (approved by SLAC)
• RTEMS based IOC
– Currently testing with a MVME6100 processor
– BSP for MVME3100 processor being developed at SLAC
– Acromag IP330A Industry Pack Module (ADC)
– GE Fanuc (SBS) IP-OCTAL-232 RS-232 Communications (Motors)
– GE Fanuc (SBS) IP-OPTOIO-8 Digital I/O (BFW solenoid/limit switches)
– 4 industry pack slots with 3 populated by above modules
2U height
UCM Software - EDM Displays
UCM Software - Current Status
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Long Term Test (LTT) area actively being assembled
RTEMS IOC is booting from SVN controlled area
– All ip modules configured and communicating
– Databases for all hardware components are progressing
Communication and motion verified for a single CAM
– With rotary potentiometer readback
UCM - Concerns
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No big technical issues
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Delivery time of the IOC racks and VME crates
Manufacturing time for 35 systems
Quality control program for assembly and testing
UCM Appendix - Support Documentation
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General Undulator System Requirements (#1.4-001)
Undulator Motion Controls (#1.4-107)
LCLS Undulator Support/Mover System Engineering Specifications (#1.4-112)
Undulator and Surrounding Thermal Monitoring Specifications (#1.4-114)
Undulator Beam Finder Wire (#1.4-004)
Technical Specifications for the Undulator Beam Finder Wire (#1.4-116)
Linear Potentiometer Cables (SLAC Drawing #CA381-011-56)
Undulator Control Module Detailed Design Document
– Technical specifications of control system components
– Expanded system details
– Relevant procedures
– Will be submitted as a controlled document in 2008
UCM Appendix - Software Development Environment
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Subversion (SVN) controlled software repository
EPICS base R3.14.9
– asyn R4-9
rs232 communications to motors
– autosave R4-2-1
ioc pv saving
– ip330 R2-5
potentiometer and RTD readbacks
– ipUnidig R2-5
BFW solenoid and limit switches
– ipac R2-9
industry pack modules support
– motor R6-3
Animatics smart motors
– seq 2.0.11*
smart monitor sequence programs
RTEMS 4.7.1 in IOC
VisualDCT (VDCT) for database development
EDM display manager
– Using templates provided by SLAC
* Library reference for iocsh needs to be removed from Makefile, it’s been consolidated into another library
UCM Appendix - Software CAM Motion Equations
UCM Appendix - Acromag IP330 ADC
UCM Appendix - GE Fanuc (SBS) IP-OPTOIO-8 Digital I/O
UCM Appendix - Dataforth RTD Module