1. Vacuum Control System for Monolith Vacuum
Hilko Spoelstra
Vacuum System Engineer
European Spallation Source ERIC

2. Outline Vacuum Diagrams Vacuum equipment and framework agreements
Vacuum control system
Requirements
Interfaces
Next steps
Conclusion

3. Beam Window Vessel Vacuum

4. Monolith Vacuum
Roughing System

5. Monolith Vacuum
High Vacuum System

6. Monolith Vacuum
Cryo Pod System

7. Vacuum equipment summary
Proton Beam Vessel
Monolith Vessel
Pirani Gauge 4 8
Cold Cathode Gauge 2
Roughing Pump 6
Turbo Pump
Cryo POD -
Pneumatic Valves 17 25
Control Valves (Butterfly)
Residulal Gas Analizers 1

8. Vacuum Equipment Standardization
Standardization of vacuum equipment through a Framework Agreement (FA)
Single suppliers for each type of equipment
Framework agreements even applicable for some of our in-kind partners
Many advantages

9. Vacuum Control System
Complete in-house design for control racks and control logic
Vacuum Group - > Hardware and Electric design (EPLAN)
Integrated Control System Group -> PLC and EPICS IOC programming
Common approach for all vacuum systems: Accelerator, Target and Neutron Instruments
Epics Domain
ICS team responsibility
Vacuum group responsibility

10. Controllers for pumps and gauges
Due to high radiation levels at many locations, vacuum equipment and their controllers are separated.
The vacuum controllers themselves are the “brains” of the system. Internal protection circuits are always active regardless of PLC or EPICS status.
Programmable threshold/interlock signals within the controllers are used for process control and interlocking.
RS232/485 serial communication is used for visualizing parameters on the OPI, archiving and setting up the vacuum controllers remotely.

11. Vacuum Control System Overview
IOC
Serial to Ethernet Server
(Moxa Boxes)
Control Racks
PLC
(CPU + Distributed IO)
Valve Interface
Turbo Pump Controller
Cryo Chiller
Gauge Controller
Residual Gas Analyser
Valves
Roughing Pumps
Turbo Pumps
Cryo Pods
Gauges
RGA
Network Communication
Digital I/O
Serial Communication

12. PLC system PLC system for process control of the vacuum system.
To keep the vacuum system in a safe state during automatic pump-down and during operation by:
Acting on threshold signals from gauges/gauge controllers
Acting on position switches from gate valves and angle valves
Acting on status signals from the vacuum pumps.
Using OPI (EPICS) screens as the user interface
Siemens S CPU + 200MP DI/DQ (ESS standard)

13. PLC System PLC System: 1 CPU Distributed IO in each rack
Technical Network
PLC System:
1 CPU
Distributed IO in each rack
Digital IO
Digital IO
Vacuum Controllers
Vacuum Controllers
Vacuum Controllers
Vacuum Controllers
Vacuum Controllers
Vacuum Controllers
Monolith Vessel Vacuum Control Rack
Beam Window Vessel Vacuum Control Rack

14. EPICS Control Panels / User Interface Archiving: Gauges (pressure)
Pumps (motor current, rpm, status)
Valve (position)
Gateway for the PLC to the controllers through terminal server

15. Gauge Control PLC Gauge Controllers Moxa Box Pirani Gauge
Digital IO
Gauge Controllers
Cold Cathode Gauge
RS232
Moxa Box
Vacuum Vessel
Vacuum Control Rack

16. Turbo Pump Control PLC Turbo Pump Controllers Moxa Box Turbo Pump
Digital IO
Turbo Pump Controllers
Turbo Pump
RS232
Moxa Box
Vacuum Vessel
Vacuum Control Rack

17. Cryo Pod Control PLC Moxa Box Cryo Pods Vacuum Vessel
Digital IO
Cryo Lines
Cryo Pods
RS232
Moxa Box
Cryo Chiller
Vacuum Vessel
Vacuum Control Rack

18. Roughing Pump Control 230/400Vac PLC Roughing Pump Vacuum Vessel
Digital IO
Roughing Pump
Vacuum Vessel
Vacuum Control Rack

19. Valve Control PLC Vacuum Valve Vacuum Vessel Vacuum Control Rack
Digital IO
Vacuum Valve
Vacuum Vessel
Vacuum Control Rack

20. Rack Requirements Requirement for each vacuum control rack:
Standard 19”, min 2000*600*1000 mm ( h*w*d )
Accessible from front and back
5 kW/3 Ph normal power 1.5 kW/1 Ph UPS power
6 Network connections
Heat load max 1 kW (forced air cooling)

21. Power Requirements In the event of a power outage:
Equipment
Quantity
Normal Power
Total
UPS Power
Neodry 300 (roughing Pump) 2
3.2 kW (1 Ph)
6.4 kW -
Neodry 36E (roughing Pump) 8
0.75 kW (1 Ph)
6 kW
Cryo Chillers
10 kW (3 Ph)
20 kW
Control Racks
5 kW (3 Ph)
10 kW
1.5 kW (1 Ph)
3 kW
Total Power
42.4 kW*
* Effective power consumption will be significantly lower during steady operation
In the event of a power outage:
The PLC system and pressure measurement system will stay on UPS power.
Pumps will turn off (normal power)
Valves will automatically close

22. Interfaces Stand alone control system
No direct interfaces with other systems
Interface with Accelerator Vacuum Interlock PLC
Last gate valve in A2T should be closed before venting/removing beam window/vessel
Either through profibus/technical network or hardwired (DIO -> DIO) or both
PVs from gauges, valves and pumps are available through EPICS for other users

23. Staff
1 Vacuum System Engineer: Rack design, Interface design, Cabling specification, FBS+ ESS Naming
1 Vacuum Electrical Technician: Rack assembly, testing
1 ICS Control Engineer: PLC + EPICS integration
Experience from Accelerator

24. Next Steps Next steps: Create component list (Vacuum group)
Create the FBS Structure + ESS-names (Vacuum group)
Specify power requirements pumps + racks (Vacuum Group)
Rack wiring diagrams EPLAN (Vacuum Group)
Cable list (Vacuum Group)
Control Screens (ICS + Vacuum)
PLC + EPICS Control Functionality (ICS)

25. Conclusion
Vacuum Control System for Monolith Vacuum and Beam Window Vessel Vacuum will be based on PLC and EPICS control
It will be designed in-house by the Vacuum group and ICS
It will follow the same concept as the vacuum controls for Accelerator and Neutron Instruments
Two control racks are needed: One for each vacuum system
Maximum power consumption for the complete vacuum system will be:
42.4kW normal power
3 kW UPS power

26. Questions?