Controls System Installation Status Ernest Williams for Controls

Controls System Installation Status Ernest Williams for Controls Department Control Systems Software Section FAC November 2008 1 Ernest Williams

Outline LCLS Control System Installation Project Staff and Assignments Schedule & the Process Cable Plant, racks and other infrastructure I&C Systems status and schedule Software Status Issues & Concerns Summary Control Systems Software Section FAC November 2008 2 Ernest Williams

Project Staff Dedicated LCLS Control System Deputy (E. Carrone) to help drive the project. E. Williams: Installation Manager. M. De Salvo: Coordination Manager. Each subsystem “owned” by a System Lead, responsible for schedule, resources and costs. Additional support provided by services from PCD. Cable Shops and Fab Shops. Controls Coordination Forum: every Thursday at 9. 00 am. Control Systems Software Section FAC November 2008 3 Ernest Williams

Plans & Process for LCLS Controls System Installation Controls installation takes place in several steps: Design, documentation, procurement and Installation of the cable plant including long haul DC and I&C cables Cables termination and connection to beam line components (Mechanical Systems) Procurement & preparation of electronics racks Installation of electronics chassis and modules including crates, IOCs, networks & timing modules in the racks Rack installation in the field, AC & cable plant connection Control Systems Software Section FAC November 2008 4 Ernest Williams

Cable Plant Design & Installation Process From the list of devices to be installed… Develop racks layout & cable tray design Generate rack profiles for electronics modules Identify DC & I&C cabling requirements & document in CAPTAR Produce installation bid package from CAPTAR and tray designs Generate installation bid package & award contract Procure trays, cables, connectors, etc. Install cable plant and terminate to beam line components

The readiness status of each Controls Subsystem is tracked weekly

The readiness status of all controls racks are reviewed weekly (sheet on Share. Point)

Rack Profiles on Share. Point For each I&C rack we track the equipment to be installed in each “row” Green – Installed Yellow – Not installed, but there are no issues Red – Cause for concern

Controls Installation Schedule Overview LTU/Undulator/e-Dump Controls Installation Overview

Control System Cable Plant & Racks Nearly 100% of cable plant is installed and terminated. All Instrumentation Racks are installed and operational Control Systems Software Section FAC November 2008 10 Ernest Williams

Control System Crates & IOCs, Modules VME Crates are all installed and operational All IOCs are installed and operational We are in the end-to-end checkout phase There are currently no anticipated major delays in completing most of the pre-beam checkout. Control Systems Software Section FAC November 2008 11 Ernest Williams

IOCs Large number of IOCs running reliably for LCLS Accelerator 136 Coldfire-based embedded IOCs Mainly used for BPM and LLRF front-end processors 104 MVME 6100 IOCs 33 MVME 3100 IOCs Beamlines will also use some number RTEMS-based IOCs for Slow controls Control Systems Software Section FAC November 2008 Ernest Williams

Magnet Power Supply Control Magnet Control System ready to support end -to-end checkout Alarm Handler, SCORE, Channel. Watcher and Archiver configs are ready Control Systems Software Section FAC November 2008 13 Ernest Williams

Safety Systems Separate talks later today on Safety Systems BCS Mature design Project is on schedule PPS The Initial Acceptance Test of the Undulator Complex has been executed. New documentation control process in place Control Systems Software Section FAC November 2008 14 Ernest Williams

MPS Systems MPS Concurrently developing new LCLS MPS Response time of less than one pulse at 120 Hz New hardware extended 1. 2 km past current MPS Non-CAMAC Ready for photon section Pre-beam checkout will begin mid November Control Systems Software Section FAC November 2008 Ernest Williams

Networks Accelerator Network Infrastructure supports I&C Ethernet and MPS The project consists of: Network architecture design Cable Plant Davis Bacon Phase IV & Phase V Contracts Fiber Termination Contract e-Controls networks Integrate with other networks: Undulator Alignment Diagnostics System Network Conventional Facilities Photon Sections SLAC Scientific Computing and Computing Services (SCCS) centralized networking groups are helping with all networks New network tech hired on to support Terri Lahey Control Systems Software Section FAC November 2008 16 Ernest Williams

Network Design Accelerator Switches reside in service buildings 911, 912, 913 and 921, and FEE Undulator accelerator switches are in service buildings B 913 & B 921 to reduce heat-load The network consists of Cat 6 long hauls between service building patch panels and cat 6 boxes at racks Tunnel walkup stations: one each COW and wireless access Other IOCs are located in service buildings: MPS, BPM, etc. Fiber Trunks support Ethernet switches and MPS Control Systems Software Section FAC November 2008 17 Ernest Williams

Davis Bacon & Fiber Contracts Phase IV: install and test cat 6 long hauls Phase V: fiber pull Fiber Termination Contract terminate and test fibers for e-beam, photon, & timing SCCS/Lahey created contract using knowledge/process learned from BC 2 fiber termination contract Control Systems Software Section FAC November 2008 18 Ernest Williams

Networks Procurements Fiber trunks purchased The order for network switches is in purchasing DIGI terminal servers have been ordered Patch panels have been ordered Remaining: fiber jumpers and FODU (Fiber Optic Distribution Units) Control Systems Software Section FAC November 2008 19 Ernest Williams

Timing System The scope is to deliver triggers and timestamp data to all subsystems requiring such. The system can be split into two parts Long-haul distribution of triggers from the EVG to EVRs in LTU and beyond Short-haul back end consisting of the HW & SW to receive the EVG timing signal and generate triggers. This is the extension of the timing for BC 2 We have a procurement for the "back end" of the timing system consisting of all the HW (fan-outs, EVRs, crates, cables) to deliver triggers to the end subsystem. Control Systems Software Section FAC November 2008 20 Ernest Williams

Beam Diagnostics Profile Monitors: OTR 30 and OTR 33 installed and checked out. Waiting on air from Central Facilities OTRDMP controls are ready but device will be installed in the tunnel this week. End-to-End checkout follows. YAGXRAY controls is in progress. Waiting on fiber pull this week. TOROIDs (Controls are ready): IM 31 (system checkout complete) IM 36 (system checkout complete) IMUNDO (waiting on cable termination) IMUNDI (waiting for device installation and cable termination this week. ) IMDMP (waiting on cable termination) Control Systems Software Section FAC November 2008 21 Ernest Williams

Beam Diagnostics (Cont’d) BPMs All new Stripline BPMs controls pre-beam checkout complete Cavity BPM controls pre-beam checkout in progress. Cavity BPM Calibration software is now in development. Control Systems Software Section FAC November 2008 Ernest Williams

Beam Diagnostics (Cont’d) Alignment Diagnostic System (ADS) Interface to EPICS in good shape undergoing checkout Control Systems Software Section FAC November 2008 Ernest Williams

Facilities HVAC EPICS Interface complete and undergoing checkout. Chiller/Boiler EPICS Interface complete and undergoing checkout LCW EPICS Interface complete and undergoing checkout Control Systems Software Section FAC November 2008 Ernest Williams

Vacuum Pump Controllers Vacuum Guage Controllers Vacuum Valve Controllers PLCs for interlocks and control Cabling and Connectors Drawing and documentation in progress and in good shape. Control Systems Software Section FAC November 2008 25 Ernest Williams

Controls Subsystem Risk Matrix Control Systems Software Section FAC November 2008 26 Ernest Williams

Test Plan and Risk Analysis Control Systems Software Section FAC November 2008 27 Ernest Williams

Testing & Checkout Strategies Rack loading & testing Will accomplish as much as possible in B 024 prior to transporting racks to the field. In-field loading (Davis-Bacon) and intra-rack cabling is less efficient. Networks and Timing will be the first system to be made operational in field to allow booting of IOCs and testing Control Systems Software Section FAC November 2008 28 Ernest Williams

Rack Assembly Area (B 024 ) B 913 & B 921 PS racks B 911 & B 912 PS racks Control Systems Software Section FAC November 2008 29 Ernest Williams

Procedure for AC Power Release to Rack Systems Purpose: To provide for safe AC power application to the individual rack distribution systems (plug molds, outlets, breaker panels, ect. ) and equipment in the racks Constraints: Ensure that with the application of AC power to each rack no electrical hazards are created via rack equipment, cable plant or conductors (either within or leaving the rack). Procedure Identify/list all potential hazards, correct or neutralize any potential electrical hazard, request and receive approval from LCLS Controls Manager and the LCLS Installation Manager (R. M. Boyce) for the release/application of AC power to identified rack. Once approval is given appropriate breakers will be unlocked and control of breakers turned over to responsible system engineer. Control Systems Software Section FAC November 2008 30 Ernest Williams

PP-6 After Contractor Turn-over & LCLS Safety Lockout PP-7 After Contractor Turn-over & LCLS Safety Lockout Control Systems Software Section FAC November 2008 31 Ernest Williams

Rear of Racks LKG-03 thru LKG-10 (12/05/06) Control Systems Software Section FAC November 2008 32 Ernest Williams

Software Installation Status All IOCs have loaded their software from a central EPICS file server. The server is ready to support pre-beam checkout and commissioning. All controls software will be installed and checked out according to a “signed off” test plan. Alarm Handler, Archiver, autosave/channel. Watcher, Channel Access Security, and SCORE ready to support pre-beam checkout and commissioning Software has been installed following the LCLS software RELEASE procedure. Control Systems Software Section FAC November 2008 33 Ernest Williams

Issues & Concerns Schedule & Resources Controls is the systems “integrator” – delays in other systems directly impact our installation. This has been the case in the Injector and BC 2 installation phases Support of operations while completing final installation and pre-beam checkout of LTU/UND/EDMP System Functionality The new MPS – pre-beam checkout will be tight Control Systems Software Section FAC November 2008 34 Ernest Williams

Summary Controls in general is in good shape for 2008 installation No major design or production issues dominate the plan There are concerns about the transfer of systems from ANL to SLAC. We will use BLMs from PEP (Thanks to Alan Fischer) We have received a draft “Hand. Over” and a draft “Detailed Software Design Document” plan from ANL A large number of sub-systems have been installed and pre -beam checkout is the major activity before Dec. 1, 2008 Control Systems Software Section FAC November 2008 35 Ernest Williams