1. LCLS Undulator Controls Status
July 11, 2007 Josh Stein - LCLS Undulator Controls Technical Lead
Outline of presentation
Technical update and challenges
Budget and cost performance
Schedule update and status

2. Power Supplies
33 Sets of Quadrupoles with Integrated X-Y Corrector Magnets require power
Correctors may not be powered initially
BiRa MCOR Power Supplies
Off the shelf product, used in PEP-II and Spear
Use 6 Amp supplies with standard fault status indicators, readback and reset control
Deployed in standard SLAC configuration
An MCOR crate contains 16 power modules, therefore 3 crates will be required
Long-haul cables ordered, rack profiles being reviewed

3. Power Supply Status MCOR Components Other Components Schedule
Ordered, some have arrived
Bulk supplies which drive the system are here
Other Components
Racks, CPUs, VME modules are here
VME crates will be ordered within 30 days
PLC system for magnet protection has partially arrived
Schedule
Racks will be populated in October
Testing will start soon after that

4. CAM Actuator calibration fixture
Completed June, 2007
Enables Undulator Assembly vendor to calibrate the cams and align the rotary potentiometers
Easily followed procedure for rapid and verifiable determination of cam maxima, minima and profile used for coefficients to the motion algorithms
These parameters are integral to the motion algorithms used by the control system

5. CAM Actuator calibration fixture

6. Undulator Control Module
Primary design challenge for the APS team
Responsible for:
Undulator motion control
Temperature measurement
Beam-Finder-Wire actuator control
Preliminary Design Review conducted on :May 21, 2007
See included PDR handouts
Committee report found nothing significantly lacking in the design or implementation of the UCM (report is included in appendix)

7. UCM: Design outline
UCM must reside in the half-height rack within the undulator hall
As such, vertical height became a design constraint
Hytec Blade IOC (with various IP-modules) chosen as the commercial platform
Custom interface chassis being designed in-house to convert SCSI hi-density connectors to field devices
Includes additional electronics including:
Bridge circuitry for RTD measurements
Comparator interlock for translation stage motion
DC Power supply for motors

8. UCM: Motion Control Animatics “smart” motors specified
Motors are serial based devices - one port per motor (7 per undulator)
Five motors responsible for the position of the Undulator via CAM movers
Two motors responsible for linear translation of the Undulator in/out of beam center
Position read-back via precision potentiometers
Rotary potentiometers connected to each CAM to verify angular position
Linear potentiometers attached to a variety of places on the undulator assembly to determine position of both the girder (via the cam movers) and the undulator strongback (via the translation movers)

9. UCM: Motion Control Software
Most challenging design problem within the UCM
Complex motion algorithm (developed by Joe Xu) determines proper motor commands to perform a move
Currently system runs ‘semi-closed loop’ with no feedback from position potentiometers
Decisions need to be made on which ‘layers’ of software APS will deliver to the LCLS - include OPI screens
Low level engineering software includes:
Raw (per motor) move instructions
Middle level software might include:
Motion of a given point on the girder (typically the quad) in 2 dimensions
Performing a ‘scan’ in one plane to leverage the BFW diagnostic

10. UCM: Motion Control challenges
At present, the known position of a particular CAM is tightly coupled to the specific rotary potentiometers connected to it
How can we replace a failed potentiometer in-situ?
Can the calibration procedure be performed in-tunnel?
At present the motion software runs in a ‘semi-closed-loop’ fashion
The motor counts are verified as being performed to assure the move request is honored
None of the absolute positioning devices are used to feed-back to the motion system
If necessary it is possible to integrate the position detectors within the motion control loop
Rough calculations suggest that the time allotted for a given move would exceed that of the PDR

11. UCM : Software deliverables
What type of API does LCLS want from the APS design team?
Presently we are working with 3 different layers of abstraction
Low level (motor counts)
Middle level (CAM degrees)
High level (Quad position in X/Y)
Nobody on the UCM design team feel that any of these challenges are insurmountable

12. UCM: Other responsibilities
Translation stage interlock comparator
Used to assure the two translation stages move in a coordinated fashion
Platinum 3-wire RTDs used for temperature measurements
Achieves relative temperature measurements within 0.5°C for long-term stability trend analysis
BFW Control
Digital I/O for moving BFW in or out of the beam (with limit-switch readback)
Analog input to determine positional accuracy (via linear potentiometer) of inserted BFW assembly using same type of linear potentiometer as the undulator position read back

13. Undulator Controls design and procurement budget
Re-baseline exercise allowed us to bring our budget closer to realistic numbers
Impact of CR in 2007 is negligible for most of the UCM and ancillary components as we were in a pure design phase during most of Q1FY07
As per project guidelines, no contingency is held ‘locally’, however all estimates are recent and we have a high-level of confidence that we will deliver within budget

14. Undulator Controls budget update
Large procurements have been put out for:
Motors
Cable Components
Linear and Rotary potentiometers
Still to be purchased
Blade IOC controller assemblies (awaiting FDR) - See delivery concerns
UCMI assemblies (awaiting FDR)
EIA and cable assemblies (released to procurement)
Other infrastructure items are being purchased by SLAC (networking, racks, long-haul cables)

15. Out for bid: 35 Different types of intra-undulator cables designed
Allows rapid connection of field devices (position potentiometers, RTDs, BFW, etc) to IOC
Award expected by the end of July; First articles expected by mid-August.
Electronics Interface Assembly design complete
Aluminum channel assembly used to route wiring from undulator components to equipment rack
Fabrication being done at ANL - expected complete mid August, 2007

16. UCM: Blade IOC Delivery concerns
Minor concern on delivery of 35 Blade IOCs in time for commissioning
Alternative design has been proposed using LCLS approved VME crates and modules
Cost difference is negligible
Schedule impact?
Need to determining a ‘drop-dead’ date to accept Blade IOC design so the schedule is not at risk due to vendor delivery problems

17. Delivery Procedure
Equipment racks will be fully populated before shipping to SLAC
A traveler will accompany each rack
The same procedure will be followed for the EIA and cable assemblies
Uncrating, checkout and assembly procedures will be written as appropriate

18. Undulator Controls Schedule Update
A large exercise was completed to integrate the entire Undulator controls schedule into one WBS under 1.4.2
All subsystems from both labs (SLAC and ANL) are now covered within 1.4.2
Vestigial tasks were removed or “zeroed”
Structure changed to correspond to the rest of the project; integrating more technical content under level 4 sections
Technically the schedule is now much more accurate and easier to track

19. Undulator Controls WBS elements
: Magnet Power Supplies
Primary Engineer: Kristi Luchini (SLAC)
Procurement and installation of magnet power supplies
Software support
: Undulator Control Module
Primary Engineer: Steven Shoaf (ANL/APS)
Design, procurement and delivery of the undulator control module
Includes software design
: Rack and cable
Primary Engineer: Rich Voogd (ANL)
Specification of all intra-undulator and long haul cables
Specification and procurement of in-tunnel and service building racks
: RFBPM Testing support
Responsible for assisting in the testing of the RFBPM design at APS

20. Undulator Controls WBS elements (continued)
: Long Term Test
Primary Engineer: Joe Xu (ANL/APS)
Specification of the long-term test controls setup
Specification and design of the undulator CAM testing fixture
: Machine Protection System
Primary Engineer: Stephen Norum (SLAC)
Specification, design and procurement of the undulator hall machine protection system
: Timing
Specification and installation of the timing sub-system within the undulator hall
: BPM
Primary engineer: Till Straumann (SLAC)
Specification of the controls interface to the RF Cavity BPMs including the A/D hardware and lower-level applications
: Vacuum
Primary engineer: Stephen Schuh (SLAC)
Interface to the vacuum components within the undulator hall
: ADS
Primary Engineer : TBD (SLAC)
Interface to the alignment diagnostic system to allow EPICS access to the alignment data

21. Major schedule milestones
UCM
FDR July,2007 (will slip)
Award Blade IOC contract August, 2007
Award First article UCMI November, 2007
Receive final UCMI February, 2008
Populated racks ready for ship to SLAC March, 2008
Intra-undulator cable contract
Award contact July, 2007
Receive final shipment September, 2007
Electronics Interface Assembly
Receive final delivery September, 2007
SLAC Installation
Begins March 2008

22. Staffing update
The APS has delivered on the promise to make the LCLS a high priority by reducing APS workload on various staff people to allow them time to work on LCLS tasks
APS Controls has committed various people in support of the Undulator Control System
Currently all APS activities in support of the LCLS Undulator Controls project are staffed

23. ANL/APS Staff in support of Undulator Controls
Josh Stein - Technical Lead
Steve Shoaf - UCM Chief designer
Rich Voogd - Cable and raceway design
Joe Xu - Algorithm design
Robert Laird - Electronics design
Stan Pasky - Procurement and vendor liason
Eric Norum - Technical consultant
Ned Arnold - Technical and managerial support

24. End of presentation