1 BROOKHAVEN SCIENCE ASSOCIATES Integrated Testing George Ganetis Integrated Testing ASAC Review October 14-15, 2010

2 BROOKHAVEN SCIENCE ASSOCIATES Outline Definition of Integrated Testing Power Supplies Electrical & Mechanical Utilities Fast Orbit Feedback Other Systems Conclusions

3 BROOKHAVEN SCIENCE ASSOCIATES Definition of Integrated Testing We have defined integrated testing as operating the various sub-systems through the control system. We plan to perform integrated testing pentant-wise in parallel to installation in other pentants This testing is done without beam. Hardware sections of the controls system has to be fully functional – network, IOCs and some servers. Monitoring, logging, alarming, and some control applications are required for all sub-systems. Some sub-systems will have applications software for verification of correct operation and location of devices. Quality Assurance features will be incorporated in these applications. Reports of tests stored in a easily accessible central location.

4 BROOKHAVEN SCIENCE ASSOCIATES Summary Table – Storage Ring Power Supplies Power Supply -Model QtyMax. Voltage Max Current Configuration Stability / Resolution ppm of max I Operation Main Dipole11200 V 450 AUnipolar Switch-Mode, Digital Regulator center point tied to GND DC 1 Quadrant Quadrupole -A -B -C -D V 22 V 30 V 175 A 200 A Unipolar Switch-Mode Analog Curr. Regulator – 2 DCCTs 1 PS per Magnet DC 1 Quadrant Sextupole -A -B -C V 60 V 16 V 120 A 165 A 120 A Unipolar Switch-Mode Analog Curr. Regulator- 2 DCCTs Model A & B = 1 PS per 6 Magnets Model C = 1 PS per 2 Magnets (3.8) DC 1 Quadrant Global Horz. & Vert. Correctors -A 9024 V 1.25 A2 Channel Bipolar Linear Analog Curr. Regulator - 4 Shunts (3.8) 2000 Hz 4 Quadrant Insertion Horz. Correctors -B 1230 V 30 AUnipolar Switch-Mode Analog Curr. Regulator – 2 DCCTs DC 1 Quadrant Skew Quad Corrector-C 3020 A Bipolar Linear Analog Curr. Regulator – 2 DCCTs (3.8) DC 4 Quadrant Alignment Horz. & Vert. Correctors -D V 22A 2 Channel Bipolar Linear / Pre-Regulator Analog Curr. Regulator - 4 DCCTs Hz 2 Quadrant Dipole Trim – Corrector -E 2715V 4 A 2 Channel Bipolar Linear / Pre-Regulator Analog Curr. Regulator – 4 DCCTs (3.8) DC 4 Quadrant Dipole Trim – Corrector -F 320 V 10 A 2 Channel Bipolar Linear / Pre-Regulator Analog Curr. Regulator – 4 DCCTs (3.8) DC 4 Quadrant There is a total of 997 power supply channels used for the storage ring

5 BROOKHAVEN SCIENCE ASSOCIATES Power Supply Configuration This configuration is used for Quadrupole magnet circuits. Two DCCTs are used, one for feedback and the other for redundant monitoring. Power Supply Controller – Performs all high level functions for the power supply – setpoint / ramp generation and diagnostic monitoring There are no local controls for the power supplies. Every thing has to go through the control system. All the power supplies components have been tested separately and final testing is when they are assemble in the equipment racks. The design incorporates a large amount of monitoring instrumentation that will be need for testing. There are 9 fast and 3 slow analog signal, ~ 8 temperature sensors, 8 digital Inputs for each power supply ( ~ 27,916 signal for the storage ring) Power Supply is made up of standard building blocks

6 BROOKHAVEN SCIENCE ASSOCIATES PS Control System Interface For One Storage Ring Cell Controls Group Responsibility PS Group Responsibility There will be a large effort in testing communications between IOC, Cell controller and PSC cards There are DVM/Scanner & 1- wire interface units in each of the 3 PS Rack Groups A,B, & C

7 BROOKHAVEN SCIENCE ASSOCIATES Block Diagram for Slow and Fast Orbit Correction PS Operation We will have application software to confirm the 10 kHz update rate of power supply setpoint and readbacks. Cabling used in the are mostly very short is already assembled & tested

8 BROOKHAVEN SCIENCE ASSOCIATES Block Diagram for Booster Mode Operation NSLS II is supplying the power supply controls hardware for the booster. There will be ~ 60 channels of ps control. Testing will be responsibility of the booster vendor. (But since we will have a considerable set of software tools already developed we be helping with the testing.)

9 BROOKHAVEN SCIENCE ASSOCIATES Power Supply Rack Configurations Within the each of the 30 cells of the storage ring there are 3 power supply rack groups. A,B&C (~90 rack groups total) Controls network switches and PS IOC shares one rack bay in rack group B. There 1 set of network switches and 1 PS IOC for each cell. The controls network will be installed and made functional very early in the installation phase. There is only a small amount of cables that leave a PS rack group – network, limited timing, PS output, Thermal Switch, & 1- wire.. This configuration is for Rack Group B

10 BROOKHAVEN SCIENCE ASSOCIATES Mezzanine - Equipment Area – 1 Cell out of 30 3-D View of Equipment Enclosures & Cable Tray Power Supply RG C Power Supply RG B Beam Instru. RG D Vacuum & EPS RG E Insertion Device RG F PPS Cabinet Power Supply RG A There will be a large number of instruments, components, & cables that will have to be installed and tested.

11 BROOKHAVEN SCIENCE ASSOCIATES Series Magnet Circuits Thermal Interlock System Ethernet SCADA/Control Network Power To Magnet Input From Thermal Switches Interlock Relay To Power Supply Controller INPUT MODULE OUTPUT MODULE Power Supply Regulator/Controller POWER SUPPLY MAGNET Thermal Switches Single PLC located in computer room This system is used when multiple magnets are powered in series. ( Dipole & sextupole) One interlock interface is located in each cell.

12 BROOKHAVEN SCIENCE ASSOCIATES Power Supply Integrated Testing Software Test applications are being developed for control, monitoring, long term logging, and alarming for power supplies on the storage ring mezzanine and injector service bldg. PS Controls/Interlocks - on/off and current setpoints & fault tests and status readbacks. Real time monitoring on analog and digital signal. Logging of power supply operating data over extended periods of time. Low & high current stability tests with temperature sensor data for power supplies, rack environment, and magnet. Test of current regulator and monitoring instrumentation. Semi-automated tests to confirm polarity of magnet field of the dipole, quad, sext, and correctors. Hall probe fixture to be interfaced into controls system and manually moved into place for each magnet. Semi-automated tests to confirm the locations and operation of temperature sensors. Either a heat source will be applied to each sensor or turning off devices to see temperature change. Manual test of thermal switches location, confirm the right switch interlocks the correct power supply. Test reports generated by controls applications as prove the tests were preformed and the data is correct. (No paper data sheets – all data stored electronically) Booster power supply applications- Ramp downloads, read-backs data plotting, and setup of timing and ramp triggers. Software tools for diagnoses of power supply faults. Applications to setup the trigger conditions for circular buffers in the PSC and read and display data from them. This testing will take a considerable amount of time, that is why we will start immediately as the equipment is installed. We have scheduled ~ 10 days of testing per cell.

13 BROOKHAVEN SCIENCE ASSOCIATES Electrical Utilities Front of enclosures This is one of 30 Cells Conduits to Tunnel AC Power Distribution 30 KVA UPS & UPS Power Distribution Temperature controlled equipment racks, Normal power & UPS power distribution to racks and various pieces of standalone equipment. “1-wire” temperature & power monitoring will be incorporated in to the distribution equipment. The UPSs are all connected to the network and will have monitoring software. Not shown are Power Line Transient Recorders located at each sub-station – All network connected.

14 BROOKHAVEN SCIENCE ASSOCIATES Electrical Utilities Almost all equipment racks are temperature controlled (~ 580 ) Equipment inlet air temp. is held constant at 24 °C. System is design to remove ~ 5 kW of heat from each heat exchanger using 13 °C chilled water. All the PID controllers are connected to the control system. ( ~ 700 units) There will be a number of “1-wire” temperature sensors that will be installed to monitor the operation of the cooling system ~ ( 4000 sensors) The “1-wire” system uses the same hardware interface with the power supply systems. Application software is in development for monitoring and logging data.

15 BROOKHAVEN SCIENCE ASSOCIATES Mechanical Utilities – Water Systems Testing will be done for all secondary DI and AL systems NSLS II is supplying control programming for these water systems. This Configuration is used in all of the 5 service building – Secondary DI & Aluminum

16 BROOKHAVEN SCIENCE ASSOCIATES Electrical & Mechanical Utilities Testing Software Same type of applications that are used for power supply testing are needed for both electrical and mechanical utilities. The utilities must be completely operational before full current power supply testing or vacuum bake-outs can be done. Applications that record that electrical utilities devices are in the correct physical location for temperature sensors, humidity sensors, rack temperature controls, water leak detection systems, current & voltage monitors, UPSs, and Power Analyzers. Applications that will confirm the operation of the water systems through the control system. The Controls system also has an interface to the conventional facilities building systems – Primary DI, Process chilled water, & HVAC. Stability runs - operation of all electrical & mechanical utilities equipment for extended times. Data will be logged for baseline data. Monitors and logger will be arranged in small groups to allow for easy testing. By cells or service bldg. Alarming function will also be tested. Test reports generated by controls applications as prove the test were preformed and the data is correct. (No paper data sheets – all data stored electronically)

17 BROOKHAVEN SCIENCE ASSOCIATES Fast Orbit Feedback System BPM system has a pilot tone calibration feature. This signal is injected right at the girder in the tunnel. Application software will be developed that will modulate this pilot tone to simulate a beam moving. The software will then record the response of the power supplies to confirm the overall system response. There are 240 BPM, 30 cell controllers, 90 fast dual plane corrector PSCs, & 180 slow dual plane corrector PSCs. Diagram supplied by Yuke Tian

18 BROOKHAVEN SCIENCE ASSOCIATES Other Systems There are a number of other systems that will have to be tested through the control system. These system will used the same set of tools for control, monitoring, long term logging, and alarming. Same type of applications that are used for power supplies will be used for verification of operations and locations of devices that these other systems will use. Vacuum systems – large number of gages, pumps, and valves will have to be tested. Controls have to be operational before bake-out can start. Interlock function into the EPS system also needs to be tested. Testing will be done on a cell by cell basis. Beam Instrumentation – Beside the BPMs there are a number of other system that will need testing, Cameras, Flags, tune measurements, etc. RF System – Low level RF, High Power RF, and cryogenic systems. There are only a few systems, but a lot of specialized testing that will take considerable effort. PPS - Personal Protection Systems – Testing of read-only function for all areas. EPS – Equipment Protection Systems – Mostly involves the control and interlocks for the front ends. Top-Off Safety – This is being defined at this time. Insertion Devices – Testing will be developed for confirming the operation of the device’s mechanical and electrical systems.

19 BROOKHAVEN SCIENCE ASSOCIATES Conclusions Very large number (tens of thousands) of signals will have to be verified that they are working and located in the correct location. Automation of this testing is required to meet schedules. The hardware designs for most systems have been done to allow this automation to occur. The various ASD groups are working with the controls group in developing the application programs needed for this testing. Low level software drivers for hardware have been progressing very well. Next step is the final version of mid-level applications. The controls group has been working on a universal set of applications that will be tailored to each groups requirements. We plan to have mockup of a power supply rack group ready by the beginning of the year. This will have production hardware. Here we will test out the software and testing procedures for power supplies. The first storage ring cell will be ready for integrated testing in the spring of 2011.