LCLSII Injector LLRF System Micro TCA Based Design

LCLS-II Injector LLRF System – Micro. TCA Based Design Zheqiao Geng 6/4/2012

LCLS-II Injector The Injector Klystron Stations • • 10 -6 for RF Gun 10 -7 for L 0 A 10 -8 for L 0 B 10 -5 for TCAV 0

Outline • • Introduction Requirements Scope Architecture and Design Cost and Schedule Lessons Learnt from LCLS Summary Slide 3

Introduction • A quick comparison of PAD/PAC and Micro. TCA solutions Slide 4

Introduction (cont. ) • Goals of the new Micro. TCA design for LCLS-II Injector LLRF System compared to the design of LCLS LLRF and the LCLS-II LLRF baseline: § Improve RF stability by introducing intra-pulse feedback for both amplitude and phase control § Improve operability, upgradability, reliability, visibility, maintainability and availability • GUI will be redesigned to be more friendly to the users • More automation will be provided for LLRF operations • Micro. TCA provides much overhead in computation power and data transfer speed which make the future upgrade of the system easier • Simplified system architecture (less chassis, less internal cabling) and built-in redundancy features of Micro. TCA will improve the reliability of the system • IPMI of Micro. TCA provides much more visibility and controllability of the system with platform diagnostics and board level remote control • Separation of analog parts which are installed in chassis with water cooling and digital parts which are installed in Micro. TCA crate make maintenance easier • Hot-swap capability of Micro. TCA reduces the mean time for repair and improves the availability of the system Slide 5

Physics Requirements • LCLS-II requirements fall within LCLS 1 Requirements • LCLS-II CDR – Table 6. 11 § Laser to Gun timing jitter: < 200 fs rms § L 0 Phase jitter: < 0. 1 deg. S rms § L 0 amplitude error: < 0. 07% rms • Requirements for LCLS-II Injector Transverse RF Deflector - PRD § TCAV 0 Phase Jitter: < 500 fs rms Slide 6

Functional Requirements • The functional requirements to LCLS-II LLRF System are identical to LCLS LLRF System § Services: Provides RF frequencies to different systems; Acts as RF actuators for Fast Feedback System § Controls: Maintains phase and amplitude stabilities for Drive Laser Systems and HPRF stations; Sets phase and amplitude for them § Diagnostics: Measures RF phase and amplitude; Diagnoses status of Drive Laser Systems and HPRF stations; Diagnoses status and performance of itself Slide 7

Scope • LLRF Frequency Reference providing various frequencies used at LLRF System, Timing System, Drive Laser Systems and others • Measurement and control of Driver Laser Systems • Measurement and control of HPRF (High Power Radio Frequency) stations of RF Gun, L 0 A, L 0 B and TCAV 0 • Measurement of Beam Phase Cavity 1 Slide 8

Interface and Context Slide 9

Hardware Architecture and Design for LCLS-II Injector LLRF System Slide 10

Architecture – LLRF Frequency Reference Improvements to LCLS Design § Redesign “ 476 MHz PLL” to replace the 119 MHz VCO with 476 MHz one to avoid phase uncertainties after power cycles § “LO and Clock Generator” provides both 119 MHz and 102 MHz clock to have more flexibilities in sampling rate § “LO and Clock Generator” and “Laser Ref Generator” use resettable frequency dividers to avoid phase uncertainties after power cycles § Measure 476 MHz signals for diagnostics § Add IPMI interface to all chassis Slide 11

Design – LLRF Frequency Reference • LLRF Frequency Reference will follow the existing design of LCLS (also the baseline of LCLS-II LLRF), which consists of 14 Chassis located in the RF Hut • Low Risks – No recent failures in the proven system. • Low noise system – Integrated Noise from 10 Hz to 10 MHz is <30 fs. 2856 MHz : 22 f. Srms 10 Hz to 10 MHz 2830. 5 MHz : 22 f. Srms 10 Hz to 10 MHz Slide 12

Design – SPAC • Use existing PAC design of LCLS (also the baseline of LCLS-II LLRF) – Build 4 Chassis • Low Risk - LCLS has had 0 PAC chassis failures since it began operations • SPACs are kept for LLRF Frequency Reference control to decouple it from the klystron controls which are done by the Micro. TCA system. Reference control is relatively simple but should be more robust to keep the reference system continuously working. Micro. TCA system tends to be maintained during MD days which may interrupt the RF operation. It is not acceptable for the LLRF Frequency Reference system. Slide 13

Architecture – High Power RF Station Control • Similar architecture used for the control of Gun, L 0 A, L 0 B and TCAV 0 Slide 14

Design – RF Support Chassis • Use existing RF Support Chassis design for LLRF AIP (new design compared to LCLS-II LLRF baseline) – Build 5 Chassis § 10 down mixers, 1 up converter and 1 klystron beam voltage conditioner • Low Risk –RF Support Chassis only combines the analog modules in LCLS PAD and PAC. No failures from beginning (Nov. 2011) of the test at LI 28 -2 Slide 15

Design – Micro. TCA System • Extend existing Micro. TCA design for LLRF AIP (new design compared to LCLS-II LLRF baseline) – Need 1 12 -slot Crate • Risk – 6 -slot system has been proved working at LI 28 -2. 12 -slot system has been successfully demonstrated at DESY; EVR AMC/RTM boards still under development Vadatech MCH UTC 002 ADLINK AMC-1000 CPU Slide 16

Design – Micro. TCA System (cont. ) • AMC ADC Board (Struck SIS 8300, Commercial) – Need 6 boards for injector LLRF § § § 4 lane PCI Express Connectivity 10 Channels 125 MS/s 16 -bit ADC Two 16 -bit DACs for Fast Feedback Implementation Twin SFP Card Cage for High Speed System Interconnects Virtex 5 FPGA Slide 17

Design – Micro. TCA System (cont. ) • AMC Timing Module (University of Stockholm) – Need 1 board for injector LLRF § § Fiber optic links w/ drift compensation ps stability AMC module is receiver and transmitter Clock, trigger and event distribution MTCA. 4 (Micro. TCA for Physics) version and RTM is under development at DESY Slide 18

Design – Solid State Sub-booster • Use the same design of LCLS (also the baseline of LCLS-II LLRF) • 1 k. W amplifier to drive 5045 klystron • Four Injector S-Band Stations § Gun, L 0 A, L 0 B, and TCAV 0 • This amplifier has no internal diagnostics § Input and out power is measured by the Micro. TCA System • Low Risk - 9 of these units have been running since LCLS started operation without a failure • SLAC purchases module and installs in chassis with power supplies and sequencing relays Slide 19

Firmware/Software Architecture and Design Slide 20

Architecture and Design of Firmware • General and configurable FPGA firmware for SIS 8300 boards § Extend the FPGA firmware designed for LLRF AIP project § Work for all RF stations with proper configuration § Implement intra-pulse feedback for both amplitude and phase control § 64 K data acquisition buffers for diagnostics § Arbitrary waveform generation from DACs Slide 21

Architecture and Design of Software • Software is deployed to Micro. TCA CPU and MCC Servers • Linux kernel drivers have been provided by hardware vendors • “AMC EVR Board Device Driver” and “BSA” LLA module will be provided by Timing System (out of LLRF scope) • “AMC ADC Board Device Driver” will use the existing implementation for LLRF AIP project • Existing LCLS PAC device driver will be used for “SPAC Device Driver” • “IPMI Device Driver” is under development • LLA of “Pulse-pulse RF Controller” will use the existing implementation for LLRF AIP project • A “System Manager” will be implemented for system status diagnostics and hardware/software management • “Automation”, “Algorithms and Procedures” and “GUI” will use the existing implementation for LLRF AIP project but need some development Slide 22

GUI – RF Station Control Panel Slide 23

GUI – Phase Control Panel Slide 24

GUI – Firmware Control Slide 25

GUI – RF Waveform Slide 26

GUI – LLRF Timing Slide 27

GUI – Data Acquisition l l Save all phase and amplitude values of the RF signals for the same RF pulse synchronously up to 65536 pulses Save all waveforms for the same RF pulse synchronously up to 2048 pulses Slide 28

Cost and Schedule Slide 29

LCLS-II Injector LLRF System Costs Comparison of overall cost of PAD/PAC solution and Micro. TCA solution Item PAD / PAC Solution Micro. TCA Solution Non-labor Cost ($K) 470. 83 447. 47 Engineer Labor (Hour) 4078 4598 Technician Labor (Hour) 2416 1760 Total Cost ($K) 1145. 58 1129. 40 Assume the labor rate is $117/hour for Engineer and $81. 8/hour for Technician. Slide 30

LCLS-II Injector LLRF System Costs Micro. TCA Solution Item Unit Cost Per $K Total Cost $K PAD/PAC Solution Item RF Support Chassis 5 10 50 PAD Preproduction Board 10 Slow PAC Chassis 4 5. 32 21. 28 PAD Production Boards 18 Slow PAD Chassis 1 5. 32 PADs Chassis Parts 67. 6 AMC ADC Board 6 6. 5 39 PAC Preproduction Board 10 RTM ADC Board 6 2 12 PAC Production Boards 14 Chassis IPMI Prototype Board 1 1 1 PAC Chassis Parts 44. 24 Chassis IPMI Board 10 0. 2 2 RF Cabling 30. 95 Chassis Control Prototype Board 1 10 10 Test Stand Equipment (VME) 41. 11 Chassis Control Board 5 2. 8 14 AMC EVR Board 1 3 3 RTM EVR Board 1 2 2 Micro. TCA 12 -slot Crate 1 4. 95 Micro. TCA Power Unit 2 1. 33 2. 66 MCH 2 2. 3 4. 6 AMC CPU Board 1 2. 55 AMC Ethernet Board 1 1 1 Digi Terminal Server 2 1. 4 2. 8 RF Cabling Unit Cost Per $K Sub Total Cost $K 235. 9 Hardware Cost for Special Parts of PAC/PAD and Micro. TCA solutions 34. 38 Sub Total 212. 54 Slide 31

LCLS-II Injector LLRF System Costs (cont. ) Labor Cost for Special Parts of PAC/PAD and Micro. TCA solutions Micro. TCA Solution Item Hour Rate $/hr Total Cost $K Engineer 2804 117 328. 07 Technician 624 81. 8 51. 04 Sub Total 379. 11 PAD/PAC Solution Item Hour Rate $/hr Total Cost $K Engineer 2284 117 267. 23 Technician 1280 81. 8 104. 70 Sub Total 371. 93 Slide 32

LCLS-II Injector LLRF System Costs (cont. ) Hardware Cost for Common Parts of PAC/PAD and Micro. TCA solutions Common Hardware Item Unit Cost Per $K Total Cost $K SSSB/Construction 99. 51 SSSB Chassis Parts 15. 31 LLRF Frequency Reference Chassis Parts 84. 00 Chiller 4. 47 Heliax Cables 31. 64 Sub Total 234. 93 Labor Cost for Common Parts of PAC/PAD and Micro. TCA solutions Common Labor Item Hour Rate $/hr Total Cost $K Engineer 1794 117 209. 90 Technician 1136 81. 8 92. 93 Sub Total 302. 82 Slide 33

Schedule • • Upgrade/design of hardware, firmware and software will be done by Jan. 2013 All hardware will be ready for rack installation by Oct. 2013 Both hardware and software will be integrated and tested at lab by Feb. 2014 Hardware and software will be installed in the RF HUT and ready for commissioning by Mar. 2014 Slide 34

Lessons Learnt from LCLS • The PAD/PAC based architecture is a bottleneck for real-time performance § Cold. Fire MCU is a major limitation of computation power, memory size and data transfer speed. PAD has limitations for 120 Hz waveform acquisition • Each PAD only has 4 ADC channels occupying 2 U or 3 U space in the rack. The ADC channel intensity is low which also makes reference tracking difficult because we can not have the reference signal measured by each PAD • A local feedback loop has to follow the path of PAD – VME – PAC with Ethernet connections. The system architecture is complex and the Ethernet communication is not robust • PAD and PAC chassis are hard to maintain after installed in the rack with cooling water connected • Software for PAD/PAC/VME system is complex. There are many pieces of software interconnected with UDP which are unnecessary and require more maintenance efforts • Poorly designed GUI for LCLS LLRF Slide 35

Summary • The design proposed in this talk tends to replace the PAD and PAC with RF Support Chassis and Micro. TCA crate. Only a small portion of the design is changed compared to the LCLS LLRF system • The Micro. TCA based design will provide a more compact and robust system architecture with significant improvement of computation power, real-time processing power and data transfer speed • The cost of Micro. TCA based design is comparable with PAD/PAC based design, but it will allow much less maintenance cost during system operation • The experience gained during the LLRF AIP significantly lower the risk to introduce Micro. TCA for LCLS-II LLRF System design Slide 36

Thank You!