Vacuum Control System for Monolith Vacuum Hilko Spoelstra Vacuum System Engineer European Spallation Source ERIC 2019-05-28

Outline Vacuum Diagrams Vacuum equipment and framework agreements Vacuum control system Requirements Interfaces Next steps Conclusion

Beam Window Vessel Vacuum

Monolith Vacuum Roughing System

Monolith Vacuum High Vacuum System

Monolith Vacuum Cryo Pod System

Vacuum equipment summary Proton Beam Vessel Monolith Vessel Pirani Gauge 4 8 Cold Cathode Gauge 2 Roughing Pump 6 Turbo Pump Cryo POD - Pneumatic Valves 17 25 Control Valves (Butterfly) Residulal Gas Analizers 1

Vacuum Equipment Standardization Standardization of vacuum equipment through a Framework Agreement (FA) Single suppliers for each type of equipment Framework agreements even applicable for some of our in-kind partners Many advantages

Vacuum Control System Complete in-house design for control racks and control logic Vacuum Group - > Hardware and Electric design (EPLAN) Integrated Control System Group -> PLC and EPICS IOC programming Common approach for all vacuum systems: Accelerator, Target and Neutron Instruments Epics Domain ICS team responsibility Vacuum group responsibility

Controllers for pumps and gauges Due to high radiation levels at many locations, vacuum equipment and their controllers are separated. The vacuum controllers themselves are the “brains” of the system. Internal protection circuits are always active regardless of PLC or EPICS status. Programmable threshold/interlock signals within the controllers are used for process control and interlocking. RS232/485 serial communication is used for visualizing parameters on the OPI, archiving and setting up the vacuum controllers remotely.

Vacuum Control System Overview IOC Serial to Ethernet Server (Moxa Boxes) Control Racks PLC (CPU + Distributed IO) Valve Interface Turbo Pump Controller Cryo Chiller Gauge Controller Residual Gas Analyser Valves Roughing Pumps Turbo Pumps Cryo Pods Gauges RGA Network Communication Digital I/O Serial Communication

PLC system PLC system for process control of the vacuum system. To keep the vacuum system in a safe state during automatic pump-down and during operation by: Acting on threshold signals from gauges/gauge controllers Acting on position switches from gate valves and angle valves Acting on status signals from the vacuum pumps. Using OPI (EPICS) screens as the user interface Siemens S7-1500 CPU + 200MP DI/DQ (ESS standard)

PLC System PLC System: 1 CPU Distributed IO in each rack Technical Network PLC System: 1 CPU Distributed IO in each rack Digital IO Digital IO Vacuum Controllers Vacuum Controllers Vacuum Controllers Vacuum Controllers Vacuum Controllers Vacuum Controllers Monolith Vessel Vacuum Control Rack Beam Window Vessel Vacuum Control Rack

EPICS Control Panels / User Interface Archiving: Gauges (pressure) Pumps (motor current, rpm, status) Valve (position) Gateway for the PLC to the controllers through terminal server

Gauge Control PLC Gauge Controllers Moxa Box Pirani Gauge Digital IO Gauge Controllers Cold Cathode Gauge RS232 Moxa Box Vacuum Vessel Vacuum Control Rack

Turbo Pump Control PLC Turbo Pump Controllers Moxa Box Turbo Pump Digital IO Turbo Pump Controllers Turbo Pump RS232 Moxa Box Vacuum Vessel Vacuum Control Rack

Cryo Pod Control PLC Moxa Box Cryo Pods Vacuum Vessel Digital IO Cryo Lines Cryo Pods RS232 Moxa Box Cryo Chiller Vacuum Vessel Vacuum Control Rack

Roughing Pump Control 230/400Vac PLC Roughing Pump Vacuum Vessel Digital IO Roughing Pump Vacuum Vessel Vacuum Control Rack

Valve Control PLC Vacuum Valve Vacuum Vessel Vacuum Control Rack Digital IO Vacuum Valve Vacuum Vessel Vacuum Control Rack

Rack Requirements Requirement for each vacuum control rack: Standard 19”, min 2000*600*1000 mm ( h*w*d ) Accessible from front and back 5 kW/3 Ph normal power 1.5 kW/1 Ph UPS power 6 Network connections Heat load max 1 kW (forced air cooling)

Power Requirements In the event of a power outage: Equipment Quantity Normal Power Total UPS Power Neodry 300 (roughing Pump) 2 3.2 kW (1 Ph) 6.4 kW - Neodry 36E (roughing Pump) 8 0.75 kW (1 Ph) 6 kW Cryo Chillers 10 kW (3 Ph) 20 kW Control Racks 5 kW (3 Ph) 10 kW 1.5 kW (1 Ph) 3 kW Total Power 42.4 kW* * Effective power consumption will be significantly lower during steady operation In the event of a power outage: The PLC system and pressure measurement system will stay on UPS power. Pumps will turn off (normal power) Valves will automatically close

Interfaces Stand alone control system No direct interfaces with other systems Interface with Accelerator Vacuum Interlock PLC Last gate valve in A2T should be closed before venting/removing beam window/vessel Either through profibus/technical network or hardwired (DIO -> DIO) or both PVs from gauges, valves and pumps are available through EPICS for other users

Staff 1 Vacuum System Engineer: Rack design, Interface design, Cabling specification, FBS+ ESS Naming 1 Vacuum Electrical Technician: Rack assembly, testing 1 ICS Control Engineer: PLC + EPICS integration Experience from Accelerator

Next Steps Next steps: Create component list (Vacuum group) Create the FBS Structure + ESS-names (Vacuum group) Specify power requirements pumps + racks (Vacuum Group) Rack wiring diagrams EPLAN (Vacuum Group) Cable list (Vacuum Group) Control Screens (ICS + Vacuum) PLC + EPICS Control Functionality (ICS)

Conclusion Vacuum Control System for Monolith Vacuum and Beam Window Vessel Vacuum will be based on PLC and EPICS control It will be designed in-house by the Vacuum group and ICS It will follow the same concept as the vacuum controls for Accelerator and Neutron Instruments Two control racks are needed: One for each vacuum system Maximum power consumption for the complete vacuum system will be: 42.4kW normal power 3 kW UPS power

Questions?