Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Single Undulator Test Status/Plans April 06 Geoff Pile

FAC: SUT Status & Plans 20 th / 21 st April 06 Revisiting the Goals of the Single Undulator Test Provide critical input to the S/M system design reviews. Help to determine whether the support/mover system design is ready for final production. Measurement of girder and rollaway motions Determine precision and reproducibility of motions, including start and stop Check for interference Measure vibration damping or (hopefully not) amplification. Measure position stability and temperature dependence of components and subcomponents.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Extract From LCLS Single Undulator Test Plan The first two weeks of the test shall be called “Short Term Tests” and there will be an additional 6-8 weeks for the “Additional testing and Evaluation Period”. The Short Term tests will be dedicated to gathering enough information to prove the prototype components and use that information to assist in the final design reviews and procurement of production components.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Integration at ANL We know the SUT is the most crucial point for engineering integration in the Undulator design at ANL. Our workforce is interactive, focused and very enthusiastic about finding and solving integration issues. It’s been tough to keep up with the schedule but we’re still on track! Formal Planning and Scheduling – 1 x week Update MS project – progress chase components – review effects Formal “On The Job” planning and scheduling – 5 x week Review today’s work – coordinate/plan tomorrow’s day

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Integration with SLAC SUT Collaboration ANL/SLAC At least five SLAC engineers have been identified to collaborate during the SUT. Hydro Leveling System and Wire Position Monitor systems It is anticipated that dummy/prototype equipment will be fitted to the SUT during the middle of May 06. SLAC design – integrated at ANL. Alignment Activities Responsible collaborators are Horst Friedsam and Catherine LeCocq. Magnetic Measurements No significant magnetic measurements are planned but magnetic testing of the 1st Article Undulator magnet(s) are being performed in the same magnet measurement facility (MM1) in parallel with the SUT tests. Zak Wolf and Isaac Wasserman Production Planning and Scheduling Assembly processes – lessons learned from the SUT - GP and Rodd Pope

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 The Current SUT Plan and Schedule is Available on ANL LCLS Project page ANL LCLS Homepage Single Undulator Test Information LCLS Single Undulator Test Plan

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 SUT Milestones (planned in early March 06) NameFinish Date Detailed SUT test plan completeFri 3/17/06 SUT Assembly CompleteFri 5/5/06 Magnet System testing completeWed 5/3/06 Support System testing completeMon 5/1/06 Vacuum System testing completeFri 5/19/06 Diagnostic System testing completeFri 5/5/06 Control System testing completeTue 6/13/06 Alignment System testing completeThu 6/1/06 SUT Complete 6/13/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Progress so Far April 06 (SUT Complete 6/13/06) Detailed SUT test plan complete: Completed 3/17/06Fri 3/17/06 SUT Assembly Complete: OK - but no WPM or HLS expected until mid May Fri 5/5/06 *Magnet System: Quad/stand & dummy Undulator installed, replacement testing now – good results Wed 5/3/06 Support System: installed, testing now – good resultsMon 5/1/06 Vacuum System: Ready –still in pre alignment –support installed and aligned Fri 5/19/06 Diagnostic System: Components available for installation now Fri 5/5/06 * Control System : Support Mover & X translation installed. Wiring issues and a “Stop work order” Tue 6/13/06 Alignment System testing complete: Target to Fit up WPM & HLS ersatz by mid May – Thermal and Vibration tests in last few weeks of SUT. Thu 6/1/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 The Quad Support Stand

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 The Quad Support Stand The stage is designed to fit in the quad footprint, has an overall height of 113 mm and can carry a 50 kg load Adjusts in X and Y directions and has been designed to be able to position Quad to <5 microns. Lower knob adjusts X Upper knob adjusts Y Initial thermal and Vibration tests are planned this week. Need to test with new dummy Quad later.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Quad support Testing in the Lab Horizontal travel is plus & minus 4 mm Vertical travel is plus & minus 2.6 mm Resolution: 3 microns is easily achievable, 2 microns requires more precise adjustment for the both of the motions. We plan to repeat all these tests using a Keyence system with the resolution up to 0.05 microns on the SUT.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Information provided by Jeff Collins SUT Undulator Segment Replacement Testing

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 SUT Undulator Segment Replacement Testing Background: The Magnetic Axis of each Undulator Segment is Fiducialized to a Fixed Horizontal and Vertical Dimension using Shim Plates Underneath and on the Ends of the Undulator Support Plates in order to make all Undulator Segments Identical and Interchangeable. When Referenced to the Undulator Alignment Pins on the Stage Transition Plates, Undulator Segments can be Interchanged Without the need for Realignment. The Total Tolerance Budget Mandates that this Process Must be Repeatable to within 180 µm rms Horizontally and 70 µm rms Vertically * (Robert Ruland’s 7/7/05 Presentation “Alignment Considerations”) In Reality, the Process Needs to be Repeatable to within a Percentage of this Tolerance to Allow for Additional Tolerance Stack Up elsewhere. Purpose: Using only One Undulator Segment, Determine the Positioning Repeatability at Both End of the Undulator after Removal and Reinstallation.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Threaded Stud Guides Undulator Support Plate Stage Transition Plate Undulator Alignment Pins

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Testing Method: Four Keyence Sensors were used to Measure the X and Y Displacement at Both Ends of the Undulator Relative to the Girder. A Laser Tracker Network was Established using Numerous Monuments around the Undulator System and Numerous Monuments on the Undulator and on the Girder. Positions were Zeroed, and the Undulator was Unbolted and Removed from the Stages using our Lifting and Positioning Fixtures. The Weight of the Undulator is Removed from the Girder using a Forklift. The Undulator is then Captured by the Lifting Fixtures and Brought back Down onto the Stages. Bolts are Retightened using a Torque Wrench and then the Final Positions are Noted from the Keyence Sensors and Compared with the Laser Tracker System Results. This Method was Repeated 6 Times for a Good Statistical Average.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Keyence Sensor Locations: X upstream : Upstream End of Undulator, Horizontal Measurement Y upstream : Upstream End of Undulator, Vertical Measurement X downstream : Downstream End of Undulator, Horizontal Measurement Y downstream : Downstream End of Undulator, Vertical Measurement Laser Tracker Monuments: UX: Upstream End of Undulator on the Outboard Side UY: Uptream End of Undulator on the Top DX: Downstream End of Undulator on the Outboard Side DY: Downstream End of Undulator on the Top G1: Upstream Outboard Corner of the Girder G2: Downstream Outboard Corner of the Girder G3: Inboard Center of the Girder

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 UX UY G1 DY DX G2 Lifting/Positioning Fixture X upstream Y upstream X downstream Y downstream

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Zero Position (µm) Final Position (µm) Change In Position (µm) X Upstream Y Upstream X Downstream Y Downstream ∆Z (µm) ∆Y (µm) ∆X (µm) UX UY DX DY G G G Laser Tracker Data: Keyence Sensor Data: Trial #1

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Zero Position (µm) Final Position (µm) Change In Position (µm) X Upstream Y Upstream X Downstream Y Downstream ∆Z (µm) ∆Y (µm) ∆X (µm) UX UY-1649 DX DY G G G Laser Tracker Data: Keyence Sensor Data: Trial #2

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Zero Position (µm) Final Position (µm) Change In Position (µm) X Upstream Y Upstream X Downstream Y Downstream ∆Z (µm) ∆Y (µm) ∆X (µm) UX UY DX DY G G G Laser Tracker Data: Keyence Sensor Data: Trial #3

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Zero Position (µm) Final Position (µm) Change In Position (µm) X Upstream Y Upstream X Downstream Y Downstream ∆Z (µm) ∆Y (µm) ∆X (µm) UX UY DX DY G G G Laser Tracker Data: Keyence Sensor Data: Trial #4

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Zero Position (µm) Final Position (µm) Change In Position (µm) X Upstream Y Upstream X Downstream Y Downstream ∆Z (µm) ∆Y (µm) ∆X (µm) UX UY7436 DX DY98265 G G23108 G37-27 Laser Tracker Data: Keyence Sensor Data: Trial #5

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Zero Position (µm) Final Position (µm) Change In Position (µm) X Upstream Y Upstream X Downstream Y Downstream ∆Z (µm) ∆Y (µm) ∆X (µm) UX5632 UY71532 DX DY G1N/A G2N/A G3N/A Laser Tracker Data: Keyence Sensor Data: Trial #6

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Conclusions: The Process of Replacing an Undulator Segment is Quick and Easy Using the Lifting and Positioning Fixtures. The Process is Very Accurate and Repeatable. The Worst Case Repeatability for Vertical Alignment is Less than 10 Microns. The Worst Case Repeatability for Horizontal Alignment is Less than 40 Microns. The Laser Tracker Network Established around the SUT Provides Excellent Results that are in Good Agreement with the Keyence Sensor Measurements. The Laser Tracker Network will be Used Throughout SUT Testing to Provide a Secondary Set of Measurements for Comparison to The Keyence Sensors and Positioning Potentiometers.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 “Stop Work Order” Control System - X translation stage At approximately 10:30am on 4/05/06 we had mechanical failures of both of the Undulator "X" translation stages. The stages were damaged due to software/operator set point errors that allowed the stages to dislodge their end stop plates. The failures have been reported to APS and SLAC management, safety officials and Tom Barsz (QA ). The minimum corrective action will be: (written 4/05/06) No ANL/LCLS support mover system motor (connected to the SUT) is to be operated until further notice.* The system will modified and then re-inspected for functionality and safety. The minimum modifications and re-commissioning procedure will be as follows: 1. Addition of Software P.V. limits, fully wired limit switches and hard stops will be installed. 2. All component cabling will be re-inspected for completeness, damage, connection quality and workmanship. 3. A test procedure for functionality checkout will be generated. ( A check off commissioning list) 4. An APS group peer review of the safety associated with the SUT,for controls and support mover system, will be held. 5 Approval from the ANL LCLS director to re-start commissioning.

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 “Stop Work Order” Control System - X translation Still in effect 4/20/06 Root Cause: Unplanned work, perceived schedule pressure. Lessons Learned: Not enough ISM. We speak it, write it, but don’t do enough of it. Had positive Safety reviews with management and peers. Scheduled “SMART Training” for LCLS Supervisors. LCLS Controls group assigns wireman and designer to SUT project to enhance quality and safety. Currently wiring and testing the positioning - potentiometers, additional limit switches and integrating Emergency Off push buttons into power circuits. Need to install hard stops and test software modifications – expect to rescind “Stop Work” 4/24/06 Has slowed us down (but in parallel with other design issues) – May have lost a few days in the schedule?

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 04/05/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 Additional SUT Construction pictures

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 03/15/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 03/15/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 03/22/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 04/03/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 04/03/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 04/05/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 04/11/06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April /06

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 “Long Term Tests” In parallel with the SUT- a completely separate “Long Term Test" (Drawings of the long-term test layout) facility is just getting underway. Half of the existing APS EAA RF area has be designated for this work. To start with the system will be constructed with prototype undulator components which will be subsequently swapped out for production components as they become available. The test area will have a full scale, twenty foot long, half-section mock tunnel. The undulator components will be located in exactly the same proximities as they will be located in SLAC’s U.H. Tunnel. It is expected that this facility will remain in place through the LCLS commissioning stages.Drawings of the long-term test layout

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 “Long Term Tests” Mock Tunnel design completed. (very Simple) Unistrut tunnel components delivered to EAA. Area preparation started – Preliminary tunnel construction starts next week. LTT will utilize MM1 (2 nd ) girder, support stands and the Metalex 1 st article undulator. Motion Controls and alignment testing moves to “Long Term Tests” end of June as SUT is dismantled. Planning and Scheduling the usage of the Long Term Test facility will be phased in as SUT nears completion

Geoff Pile FAC: SUT Status & Plans 20 th / 21 st April 06 First Article MM1 04/17/06