The Implementation Strategy
Proposed SLAC Controls Upgrade
December 1, 2010
Ray Larsen
Outline
1.
2.
3.
4.
5.
Existing System
MTCA Module Development
Single Station Upgrade Demo Plan
Production & Test Plan
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
Short cables top of
penetration would need
elongation to new rack
KEEP OUT AREA FOR KLYSTRON REPLACEMENT
72"
Penetration
POSSIBLE NEW
DOUBLE BAY RACK
LOCATION
Support
Post
Klystron
48"
14"
48"
Fiat Racks
24"
48"
24"
POSSIBLE NEW DOUBLE BAY RACK LOCATION
28"
Possible Obstructions
Sub-Booster (22")
Arc Flash Boundary (12")
Storage (6-42")
Transformers (~36")
Other Racks
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Possible Obstructions:
Keep Out Area
PFN Tuning
28"
Keep Out Area
T20 Replacement
(Can be shifted 6ft to the right)
40"
Modulator
Controls Upgrade Implementation
Arc Flash Boundary
Storage
Transformers
Other Racks
4
WG & Cable
Penetration
to Tunnel
Existing Linac Klystron Station RF Control, Monitoring, and Interlocking System
IPA Chassis
Controls RF Phase and
Amplitude
PAD Chassis
Measures RF Phase and
Amplitude
PIOP CAMAC
Module
Controls IPA, PAD,
and MKSU. Interface
to control system
MKSU Chassis
Interlock and Control for
Klystron SLED Support
Systems
Existing
Controls
Racks
New system will combine
the PAD, IPA, and part of
the PIOP into the RF
Control System
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Controls
Controls
Upgrade
Upgrade
Implementation
Implementation
6
PIOPs (4)
PDU Timing
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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
4 DUAL DIFFERENTIAL
SHLD’D PAIRS
12V PWR, GND, JTAG,
IPMI
HOT SWAP, PWR IPMI
EJECTION LOGIC
REAR I/O
AMC
56 DUAL DIFFERENTIAL
SHLD’D SIGNAL PAIRS
IPMI MMC
CONTROLLER
FPGA
DC-DC CONVERT
HOT SWAP IPMI
EJECTION LOGIC
SERIAL Gb
BACKPLANE
RTM
 Double-wide
plus RTM
provides
excellent
analog space,
ground noise
control,
crosstalk
 AMC space
fully backward
compatible
with industry
single-wide
designs
 Reference Design complete w/ supporting FW-SW environment enables engineers
to focus on payload design w/ power, IPMI basic infrastructure standardized
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Controls Upgrade Implementation
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.
5.
6.
7.
Profile Monitor Beam Length (BLEN)
Vacuum gauge controller interface
Vac-ion pump controller interface
Wire scanner movers (Hytek)
• PMC Card AMC Adapter
8. Fast Frame grabber for Profile Monitor
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Beamline BPMs, Toroids, Gated ADCs
Strategy:
AMC 1
FAST ADC
4 CH 16 BIT 119 MSPS
(180 MSPS MAX)
RTM 1
STRIPLINE BPM
(2 TYPES)
SIGNAL CONDITIONING,
FILTERING &
CALIBRATION
RTM 2
TOROID (2 TYPES)
SIGNAL CONDITIONING &
CALIBRATION
(Struck,
Vadatech,
Libera)
RTM 2
GATED ADC SIGNAL
CONDITIONING (GADC)
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 Encourage
Industry to provide
key generic
complex AMC
modules
Develop 2 or
more sources
Encourage
multiple labsupported
specifications
LLRF System, Feedback Apps
2856 MHZ
REF IN
AMC 2
FAST ADC
10 CH 16 BIT 119 MSPS
2 CH DAC 238 MSPS
RTM-3
25 MHZ IF SIGNAL PASSTHROUGH
DAC OUTPUT TO RF AMP
I/O CNTRL
IF SIGS
DAC OUT
(Struck,
Vadatech
Libera)
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RTM-3
GENERIC FAST
SIGNAL CONDITIONING UP TO 10
CH ANALOG IN, 2 CH DAC OUT
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RF FREQUENCY GENERATION
LOCAL OSCILLATOR (LO)
SAMPLING CLOCKS
8 CH DOWNCONVERTER
Beamline Instruments via IP Adapter
AMC 3
3-INDUSTRY PACK (IP)
ADAPTER FOR PHYSICS
BACKPLANE
RTM 4
BLEN BROFILE MONITOR
GENERIC 3 IP 1/0
ADAPTER, SCSI PORT,
IPMI PASSTHOUGH
RTM 4
VACUUM GUAGE
READOUT, REMOTE
WAKEUP
1-3
INDUSTRY
PACKS
(TEWS,
Vadatech)
RTM 4
VACI-ION PUMP
CONTROLLER
INTERFACE
RTM 4
WIRE SCANNER MOVERS
HYTEK IP DESIGN
PORT FW, SW FROM
XSTG DESIGN
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High BW Frame Grabber PMC Adapter
GENERIC
ADAPTER E.G.
VADATECH,
TEWS
FIBER OPTIC
MULTI- GIGABIT
LINKS
RTM 5
SIMPLE INTERFACE
PASSTHOUGH FOR PMC
E.G.PROFILE MONITOR
HIGH DATA BW FAST FRAME
GRABBER
AMC 4
PMC ADAPTER
(TEWS,
Vadatech)
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STANDARD
PMC BOARD
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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
40ft ACCEL.SECTION
INSTRUMENTS
& CNTRLS
MAIN DRIVE LINE
BPMs
Toroids
Wire Scan
Profile Mon.
Vacuum
Power Supplies
BCS
Temperature
SYNC CLOCKS &
LO GENERATION
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Station Crate Layout (Typ.)
2
3
4
5
6
7
8
9
10
11
12
t
e
x
t
POWER UNIT 1
MCH HUB CONTROLLER & MGR
WIRE SCANNER MOVER
VACUUM GAUGE
VAC-ION PUMP
SLOT
SPARE
ENET
INTERFACE
TOROID
BPM2
BPM 1
FPGA INTERLOCK SUM
FAST ADC-DAC 10-2 CH
TIMING MODULE
IOC PROCESSOR
1
PROFILE FRAME GRABBER
t
e
x
t
MCH HUB CONTROLLER & MGR
t
e
x
t
POWER UNIT 1- REDUNDANT
PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)
te
xt
t
e
x
t
PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)
Infrastructure
Pwr, MCH, IOC,
Timing
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RF Controls Modules (Typ.)
Fdbk
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Redundant
MCH, Pwr
Options
20
Side View Crate, AMC, RTM
AIR OUT
I/
O
I/
O
INPUT/OUTPUT SIGNAL
CONDITIONING
FRONT END MODULE
text
ADVANCED
MEZZANINE CARD (AMC)
B
B
A
P
C
K
C
PL
O
A
N
N
N
E
AIR IN
REAR TRANSITION MODULE
(RTM)
USER DEFINED I/O CONNECTORS
FAN TRAY-HOTSWAP
FAN TRAY-HOT SWAP
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)
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6 Slot Crate
w/ AMC & RTM
(Schroff)
22
Upgraded Station Rack Profile
AC POWER
PANEL
RF IN-OUT
RF GENERATION &
DOWNMIX
MKSUII
9
10
11
12
t
e
x
t
POWER UNIT 1
WIRE SCANNER MOVER
8
MCH HUB CONTROLLER & MGR
7
PROFILE FRAME GRABBER
6
VAC-ION PUMP
5
VACUUM GAUGE
4
BPM2
BPM 1
3
ENET INTERFACE
FPGA INTERLOCK SUM
2
TOROID
TIMING MODULE
1
FAST ADC-DAC 10-2 CH
IOC PROCESSOR
t
e
x
t
POWER UNIT 1- REDUNDANT
MTCA
CONTROLS
MCH HUB CONTROLLER & MGR
PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)
t
e
x
t
te
xt
t
e
x
t
PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)
SOLENOID POWER
SUPPLY
HEAT
EXCHANGER
CROSSCONNECT
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CONTROLS
IN-OUT
23
In-Rack Crate Enclosure
RF CABLES TO/
FROM TRAYS
RF GENERATION &
DOWNMIX
MKSUII
11
12
I/
O
I/
O
INPUT/OUTPUT SIGNAL
CONDITIONING
FRONT END MODULE
te
xt
t
e
x
t
text
ADVANCED
MEZZANINE CARD (AMC)
B
B
A
P
C
K
C
PL
O
A
N
N
N
E
AIR IN
REAR TRANSITION MODULE
(RTM)
USER DEFINED I/O CONNECTORS
10
t
e
x
t
POWER UNIT 1
9
AIR OUT
FAN TRAY-HOTSWAP
MCH HUB CONTROLLER & MGR
8
WIRE SCANNER MOVER
7
PROFILE FRAME GRABBER
6
VAC-ION PUMP
5
VACUUM GAUGE
4
BPM2
3
TOROID
BPM 1
2
ENET INTERFACE
TIMING MODULE
FPGA INTERLOCK SUM
1
FAST ADC-DAC 10-2 CH
IOC PROCESSOR
POWER UNIT 1- REDUNDANT
t
e
x
t
MCH HUB CONTROLLER & MGR
PLUG-IN COOLING UNIT (BOTTOM IN – REAR OUT)
t
e
x
t
REAR I/O CABLES
TO/FROM RTM’S
FAN TRAY-HOT SWAP
PLUG-IN COOLING UNIT (FRONT IN – TOP OUT)
WATER COOLED
ENCLOSURE
SOLENOID POWER
SUPPLY
CABLES TO/
FROM TUNNEL
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PENETRATION
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
RTM Connector
AMC Connector
10 Ch 16 bit 125 MSPS
2 Ch 16 bit DAC output
Virtex 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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Upgrade
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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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GALLERY
INFRASTRUCTURE
UPGRADE
RACKS IN SITU
OR PROCURE
NEW
EEIP RACKS
UPGRADE
ENCLOSURE
LCW HEAT
XCHGR
CONTROLS
PROCURE ALL
MODULAR COTS
COMPONENTS
FABRICATE ALL
IN-HOUSE
COMPONENTS
(CONTRACT)
CONVERT
CABLE
CONNECTORS
RF SUBSYSTEM
PROCURE ALL
MODULAR COTS
COMPONENTS
FABRICATE ALL
IN-HOUSE
COMPONENTS
(CONTRACT)
CONVERT RF
INTERLOCK
CABLE
CONNECTORS
POWER
CONVERSION
CONTROLS & RF CONVERSION PLAN 12-1-10
UPGRADE
MODULATOR
INTERFACE
PREPARE
MODULATOR
INTERFACE(OLD,
NEW)
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INSTALL TIMING
PREPARE
SOLENOID PS
INTERFACE
INSTALL ENET
LOAD CRATES
IN ASSY SHOP
LOAD RACKS IN
SITU(IF XSTG)
INSTALL (IF
NEW)
ATTACH
STATION
CABLES
COMMISSION
STATION
LOAD RACKS IN
PCD ASSY
SHOP(IF NEW)
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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
- Contributed by T. Himel
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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.
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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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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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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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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 turnon.
• Schedule check-out time during the FACET turnon
• Repeat above steps for other
systems/sectors/downtimes until done.
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END OF SLIDES
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