806a76df - 1.1 - Instrumatation and Control Architecture.pdf

ITER UPPER WIDE ANGLE VIEWING SYSTEM PROJECT

55.GA Instrumentation & Controls (I&C) Hardware and Software

Architecture Technical Design Description

Sponsored by Oak Ridge National Laboratory c/o Princeton Plasma Physics Laboratory

Under Subcontract No: S013437 Prepared by General Atomics

304243-R00030

Revision B GA Project 30424

PPPL APPROVAL

VERSION Date Signatory QA Engineer SE External

ITER

Reviewer

Approver

1.1 9/5/2024

Mark Smith Patrick Temple Pete Dugan N/A Ravinder Bhatia

SEE EDRM

Notification

N/A

304243-R00030 Revision B

ITER WIDE ANGLE VIEWING SYSTEM PROJECT

55.GA UWAVS INSTRUMENTATION AND

CONTROL ARCHITECTURE

Sponsored by Oak Ridge National Laboratory c/o Princeton Plasma Physics Laboratory

Under Subcontract No: S013437

Prepared by General Atomics PO Box 85608

San Diego, CA 92186-5608

GA PROJECT 30424

R el ea se d

4/

/0

R eleased 2024/09/05

55.GA UWAVS Instrumentation and Control Architecture 304243-R00030/B ii

REVISION HISTORY

Revision Date Description of Changes

A 2024/06/25 Initial Release

B See Watermark

Revised power collection and head load analysis table, added specs for IR and VIS cameras, added UWAVS measurement table with measurement number, updated software architecture diagram figure 41.

POINT OF CONTACT INFORMATION

PREPARED BY:

Name Position Email Phone

Maithili Groh I&C Engineer Maithili.Groh@ga.com 858-455-3315

Daniel Finkenthal I&C Engineer dfinkenthal@palomarsci.com 858-455-2354

Sebastian Miranda I&C Engineer smiranda@palomarsci.com 858-455-2345

APPROVED BY:

Name Position Email Phone

David Chan Quality Engineer David.Chan@ga.com 858-455-3532

Sean McCartney Lead Engineer Sean.McCartney@ga.com 858-248-6652

Anthony Gattuso Program Manager Anthony.Gattuso@ga.com 858-455-2910 ea se d

4/

/0

R iii

TABLE OF CONTENTS

REVISION HISTORY .................................................................................................................. II

POINT OF CONTACT INFORMATION ....................................................................................... II

ACRONYMS ............................................................................................................................. VI

1 INTRODUCTION

1.1 Purpose

1.2 UWAVS System Layout

1.3 UWAVS System Description

2 HIGH-LEVEL HARDWARE ARCHITECTURE

3 INDEPENDENT UWAVS PORT CONTROL SYSTEM (PORT 02, 08, 11, 14,17)

3.1 Control System Architecture

3.2 UWAVS Port Subsystem Design

3.3 Calibration Strategy

3.4 Mirror Cleaning System

3.5 Shutter Control System

3.6 Image Acquisition and Processing System

3.7 COTS Checklist

4 CUBICLE CONFIGURATION

4.1 Cubicle Layouts

4.2 Power Allocation and Heat Load Analysis

4.3 Cubicle Cooling Configuration

4.4 Cubicle Enclosure Types

4.5 Cubicle Cable Entries

4.6 Network Interface

4.7 LCC Bill of Material

4.8 Cubicle Locations

5 EARTHING CONCEPT

6 SOFTWARE ARCHITECTURE

6.1 Software Architecture Overview

6.2 UWAVS Software Flux

6.3 Fast Controller(s) Time Synchronization

6.4 UWAVS Software Architecture

6.5 Master Controller (Separate for each UWAVS port)

6.6 User Interface (HMI)

7 REFERENCES

ea se d

4/

/0

R iv

LIST OF FIGURES

Figure 1. 55.GA ports around the tokamak

Figure 2. Illustration of a single 55.GA port

Figure 3. Illustration of the instrumentation and controls for 55.GA single port

Figure 4. Top level architecture representative of port 14

Figure 5. BEOC instrumentation and BEOC calibration sources location

Figure 6. 55.GA design breakdown into sub systems

Figure 7: Active alignment signal chain

Figure 8. Active alignment system (a) Components (b) detailed instrumentation on A40 mirrors

Figure 9. A40-M2 mirror subassembly physical architecture. Mirror (a) normal, (b) side, and

(c) rear isometric views. Some components transparent for clarity

Figure 10. Photos of a typical UWAVS mirror mount and radiation-hardened stepper motor

Figure 11. Photos of a typical UWAVS mirror mount and radiation-hardened stepper motor

Figure 12. Rad-resistant miniature limit switch from Crouzet

Figure 13. Stepper Motor Control system components from Physik Instrumente

Figure 14. Different types of Calibrations during UWAVS measurement

Figure 15. BEOC calibration source location with respect to cameras

Figure 16. Picture of the Model 458-4 LED-Standard Lamp with Integrating Sphere

Figure 17. Model M330 Blackbody Source (shown without customization)

Figure 18. Inside of the enclosed Model M330 Blackbody Source. The internal assemblies will be removed from the enclosure for integration directly in the BEOC. The controller will be located in the diagnostic hall

Figure 19. Transmission monitoring filament control scheme

Figure 20. (a)First mirror locations and instrumentation in Bullnose (b) MIC cable routing to first mirrors delivering RF power

Figure 21. 55.GA mirror cleaning signal chain

Figure 22. RF mirror cleaning system schematic, simplified to show the basic RF system elements

Figure 23. Commercial 60 MHz, 1 kW RF generator

Figure 24. Active Matching Network

Figure 25. In-vessel shutter architecture shown without calibration filament and cables

Figure 26. Shutter control box schematic for 55-GA.A0 extracted from the P&ID

Figure 27. DAQ MTCA.4 I/O Chassis

Figure 28: HDEC PC Computer

Figure 29. Caen power supply for camera

Figure 30: Schneider Circuit Breaker

Figure 31. Filter wheel Assembly with its components

Figure 32. I&C functions of filter wheel

Figure 33. Front-views of the two cubicles used for each UWAVS installation, designated “Camera Cubicle” and “Support Cubicle.”

Figure 34. 55.GA “Camera Cubicle” LCC layout

R el ea se d

4/

/0

R v

Figure 35. 55.GA “Support Cubicle” LCC layout

Figure 36. 55.GA “Common” LCC layout

Figure 37. Illustration showing of the Tokamak Building showing the location of the spare cubicle

Figure 38. Space Allocation requested for the 55.NE.X0 Shared Cubicle Cubicle (as per

ITER_2P3MJ2)

Figure 39. Illustration showing locations of UWAVS Cubicles

Figure 40. 55.GA earthing concept

Figure 41. UWAVS Software Structure for Cubicles

Figure 42. Software Flux

Figure 43. Fast Controller Time Synchronization

Figure 44. UWAVS software architecture for PCF

Figure 45: UWAVS software architecture for Master Controller

LIST OF TABLES

Table 1. 55.GA Measurement Contributions

Table 2. Regions, components, and associated instrumentation

Table 3: Stepper Motor ‘Pre-Set’ Positions Based on Temperature

Table 4. Active Alignment I&C Components per Port

Table 5. I&C Summary of IR and VIS Calibration

Table 6. BEOC Calibration BOM

Table 7. Transmission Monitoring BOM

Table 8. Thermal Calibration BOM

Table 9. Mirror Cleaning BOM

Table 10. Shutter Control System BOM

Table 11. Technical Specifications of Infratec ImageIR 10300

Table 12. Technical Specifications of EMV HT-12000

Table 13. Technical Specifications of Mikrotron EoSens 4CPX6

Table 14. COTS Checklist for IR camera

Table 15. COTS Checklist for EMV HT-12000

Table 16. COTS Checklist for Mikrotron EoSens 4CPX6

Table 17. COTS Checklist for 6.1.3. Caen Power Supply

Table 18. COTS Checklist for Motor Controller

Table 19. COTS Checklist for RF generator

Table 20. COTS Checklist for RF Active Matcher

Table 21. COTS Checklist for Keysight N6700 Power Supplies

Table 22. COTS Checklist for Blackbody Source Controller – Advanced Energy M330

Table 23. Power and Heat Load Requirements for Camera Control Cubicles

Table 24. Power and Heat Load Requirements for Support Cubicles

Table 25. Power and Heat Load Requirements for Common Cubicle

R el ea se d

4/

/0

R vi

Table 26. Power and Heat Load Requirements for NEX0 Shared Cubicle

Table 27. Network Interface Requirements

Table 28: LCC Bill Of Material (One Camera Cubicle)

Table 29: LCC Bill Of Material (One Support Cubicle)

Table 30: LCC Bill Of Material (BEOC Shielded Enclosure)

ACRONYMS

Acronym Description

ADC Analog to Digital Converter

BEOC Backend Optics & Camera

BOL Bio-Shield Optical Labyrinth

BOM Bill of Material

CBD Cabling Diagram

CDA Clean Dry Air

CODAC Control, Data Access and Communication

COTS Commercial Off-The-Shelf cRIO compact Real-time Input-Output

CU Cubicle (Instrumentation)

CWS Chilled Water Supply

CP Closure Plate

DAN Data Archive Network

DAQ Data Acquisition

DC Direct Current Voltage

DSM Diagnostic Shield Module

EFT Electric Feed Through

EPICS Experimental Physics and Industrial Control System

FDR Final Design Review

FPGA Field-Programmable Gate Array

FEOMS Front End Optics Modular System

FEOT Front End Optics Tube

I&C Instrumentation & Control

IOT Interspace Optical Tube System

IR Infra-Red

IS Integrated Sphere

R el ea se d

4/

/0

R vii

Acronym Description

LAN Local Area Network

LCC Local Controller Cubicle

MCB Miniature Circuit Breakers

MHz Mega-Herz

MIC Mineral Insulated Cable

MicroTCA Micro Telecommunications Computing Architecture

MC Mirror Cleaning

MXI Multisystem Extension Interface

NDS Nominal Device Support

OS Operating System

P&ID Piping & Instrumentation Diagram

PCDH Plant Systems Design Handbook

PCF Fast Plant Controller

PCS Plasma Control System

PCSS Port Cell Support Structure

PDR Preliminary Design Review

PFD Process Flow Diagram

PoE Power Over Ethernet

PON Plant Operations Network

PSD Position Sensing Detector (optical)

PSH Plant System Host

PC Port Cell

RF Radio Frequency

SDN Synchronous Data Network

SDS System Design Specification

SLD Single Line Diagram

SRS System Requirements Specification

TCN Timing Control Network

UWAVS Upper Wide Angle Viewing System

VIS Visible ea se d

4/

/0

R

1 INTRODUCTION

1.1 Purpose

This document is a description of the preliminary electronics design of the ITER 55.GA Upper

Wide-Angle Viewing (UWAVS) System. The UWAVS system plays a critical role in diagnostics, requiring robust Instrumentation and Control (I&C) solutions across systems engineering, software engineering, and electrical engineering. All levels of design and implementation must adhere to standards established in the ITER Plant Systems Design Handbook (PCDH) [1].

The Instrumentation and Control Architecture document provides an overview of UWAVS diagnostics. This document describes, Overall, I&C system and diagrams

Brief description of I&C components and subsystems

Cubicle design and cubicle layouts

Power and Heat load analysis

Brief description of UWAVS Software Architecture, explanation of functionality and performance requirements

List of Human Machine Interface (HMI) screens and their brief description

Note: This document is intended to convey the hardware design of the 55.GA (UWAVS) System.

While faithful to the official diagrams, this description is not meant to serve as a detail design of specific hardware, layouts, or cabling. Design details can be found in the official Piping &

Instrumentation Diagram [2], [3], [4], [5], the Cabling Diagram [6], [7], [8], [9], the Single Line

Diagram [10], [11], [12], [13] , and the Process Flow Diagram [14], [15], [16], [17].

1.2 UWAVS System Layout

UWAVS diagnostics is positioned in 5 different ports, namely, Port 02, Port 08, Port 11, Port 14, and Port 17. Notably, the instrumentation across all 5 ports is identical. Throughout the beamline, motors and sensors are strategically placed, with signals routed to and from them to the back-end optics and cameras (BEOC), and diagnostic hall, spanning over length > 100 meters.

This document describes subsystems and instrumentation for UWAVS system. There are two cubicles dedicated to each port that house controllers, MTCA (Micro Telecommunications

Computing Architecture) chassis, and other instrumentation specific to that port. The cubicle layouts differ between Port 08, Port 11, Port 14 compared to Port 02 and Port 17. The differences are described in Section 4 of this document. A schematic layout of the UWAVS ports around the tokamak is shown in Figure 1. The regions shown are subjected to different environmental

R el ea se d

4/

/0

R conditions, therefore components, cables, instrumentation is chosen based on these requirements. Detailed mechanical designs for these ports are documentedin [18], [19], [20], [21]

The UWAVS diagnostics has total of five port located around the tokamak vessel. Ports (02, 08, 11,14) have FEOMS and Port 17 has FEOT. Even though the mechanical design differs between ports, the instrumentation in FEOMS and FEOT, and control strategy is the same. Detailed mechanical design for these ports can be found in the Front End Optical Module System Technical

Design Description [18]. UWAVS ports around the tokamak vessel are shown in Figure 1.

Figure 1. 55.GA ports around the tokamak

Typical UWAVS port with its subassemblies and some of the instrumentation is shown in

Figure 2 below for better understanding of physical space I&C equipment occupies.

R el ea se d

4/

/0

R

Figure 2. Illustration of a single 55.GA port

1.3 UWAVS System Description

The UWAVS System is a key plasma diagnostic for ITER and is designed to provide real-time view to the Divertor region (65% outer divertor, 60% of outer baffle, 15% of the inner baffle, and

45% of dome area) [22] in both IR (infra-red) and Visible spectrum. UWAVS serves primary role in basic control, machine protection, and advanced control. Aside from this function UWAVS also serves ITER diagnostic by collecting and archiving critical information to be studied for physics measurements. UWAVS system uses two IR cameras, and 2 Visible cameras to provide 1-color measurement and 2-color measurement used by PCS (plasma control system). UWAVS measurements requirements, as defined in Annex B [22], are shown in Table 1.

The 55.GA (UWAVS) system is a large and complex diagnostic with a multitude of I&C

(instrumentation and control) requirements. The system has most of the equipment located in

BEOC (back-end optics & cameras) and diagnostic hall. UWAVS also has several temperature sensors located throughout the beamline. An instrumentation diagram for UWAVS is shown in

Figure 3. This is intended to provide a simplified overview. Fast controllers, and slow controllers are in the diagnostic hall cubicles. The signals are routed via specially selected cables based on radiation and environmental exposure. There are thermocouples located throughout the beamline to provide temperature gradient and health of the optics.

ea se d

4/

/0

R

Table 1. 55.GA Measurement Contributions

DiagSyst

DiagRoleName RoleName MeasName ParameterName ConditionName RangeValue

TimeFreq

SpatialWave Accuracy Meas Para Num _Name Resol

55.GA Primary 1a.1 MP

16. Divertor operational

Max. surface

200-400 °C 400-3600 °C

10 ms ‐ 20% 10%

MP039

parameters temperature

17. First wall

(FW)

FW Surface

All heating ports, upper strike region, dome, 30%

55.GA Primary 1a.1 MP visible image & wall temperature luminance baffle. > 50 % of rest, absolute, 1%

MP042

evenly distributed.

40 ‐1E5 cd / m2

10 ms 3 mm relative

55.GA Primary 1a.2 BC

(FW) visible image & wall

FW Surface

All heating ports, upper strike region, dome, 200- 400°C

10 ms 5 mm 20°C 10°C

MP043

temperature temperature baffle. > 50 % of rest, 400- 3600°C evenly distributed.

55.GA Primary 1b. AC

38. Heat loading profile Power load Default

0.1 ‐ 25 MW m‐2

0.5-10 ms

3 mm 10% MP085 in divertor

55.GA Primary 2. PHY

38. Heat loading profile Power load

Disruption (fast window mode)

0.02 ‐ 5 GW m‐2

0.5 ms 3 mm 20% MP085 in divertor

55.GA Primary 1b. AC

38. Heat loading profile

Surface Fast-window

1000 ‐ 3600 °C

0.5 ms 3 mm 0.1 MP086 in divertor temperature

55.GA Primary 1b. AC

38. Heat loading profile

Surface

Full-frame Fast-window

200 ‐ 1000 °C

10 ms 2 ms

3 mm

20% in 200- 400°C 10% in 20% in 400- 3600°C

MP086

in divertor temperature

(FW) visible image & wall

FW surface temperature

Full-frame mode

10ms

55.GA Primary 2. PHY temperature during ELMs, FW

400 ‐

5 mm 20°C MP044

Fast-window mode

2-10ms

55.GA Back Up 1a.2 BC

35. Impurity and D,T

GD, GT

1E19 ‐ 1E25 at s‐

1 ms 50 mm 30% MP079 influx in divertor

55.GA Back Up 1a.1 MP

35. Impurity and D,T

GBe, GC, GW

1E17 ‐ 1E22 at s‐

1 ms 50 mm 30% MP078 influx in divertor

R el ea se d

4/

/0

R

14. H‐mode, ELMs and L‐ H transition

Main/divertor plasma

MP030

55.GA Back Up 1a.1 MP indicator ELM Da bursts Full-frame Fast-window

10 ms

0.5 ms one site

14. H‐mode, ELMs and L‐ H transition

Main/divertor plasma

MP033

55.GA Back Up 1a.2 BC indicator L‐H Da step Full-frame Fast-window

10 ms

0.5 ms one site

02. Plasma position and

Divertor channel

55.GA Supplementary 1a.2 BC Ip > 3 MA ‐ 10 ms ‐ 10 mm MP002 shape location (r dir.)

02. Plasma position and

Divertor channel

55.GA Supplementary 1a.2 BC shape location (r dir.)

Ip quench ‐ 10 ms ‐ 20 mm MP002

31. Escaping alphas and

First wall flux, a/10 along poloidal

55.GA Supplementary 1b. AC fast ions Non‐Alphas Steady State

0.2 ‐ 20 MW m‐2

0.5 - 10 ms direction

20% in 200- 400°C 10% in 400-

MP072

First wall flux, 55.GA Supplementary 1b. AC fast ions Non‐Alphas Transients

0.2 ‐ 20 MW m‐2

0.5 - 10 ms direction

20% in 200- 400°C 10% in 400-

MP072

First wall flux, 55.GA Supplementary 2. PHY Steady State

0.1 - 5 MeV

0.5 - 10 ms direction 20% MP071 fast ions Alphas

First wall flux, 55.GA Supplementary 2. PHY Transients

0.1 - 5 MeV

0.5 - 10 ms direction 20% MP071 fast ions Alphas

55.GA Supplementary 1a.1 MP

12. Impurity species Cu Influx ‐

1E15 - 5E18 m- 2.s-1

10 ms integral 10% MP023 monitoring

55.GA Supplementary 1a.2 BC

12. Impurity species

Extrinsic (Ne, Ar, ‐

1E16 - 2E19 m- 2.s-1

10 ms integral 10% MP025 monitoring Kr) influx

55.GA Supplementary 1a.1 MP

12. Impurity species W influx ‐

1E14 - 5E17 m- 2.s-1

10 ms integral 10% MP027 monitoring

R el ea se d

4/

/0

R

Figure 3. Illustration of the instrumentation and controls for 55.GA single port el ea se d

4/

/0

R

The UWAVS components and their associated instrumentation are listed in Table 2. The components labeled SIC-2 are monitored and controlled by ITER. All other instrumentation is monitored and controlled by UWAVS diagnostics.

Table 2. Regions, components, and associated instrumentation

Region UWAVS Component UWAVS Instrument QTY Safety Class

In vessel

A10 Mirror Module (Bullnose)

Thermocouple 3 --

First Mirror assembly 2 --

IR Cal source 2 --

A20: Mirror Module #2 Thermocouple 2 --

A30: Mirror Module #4 Thermocouple 1 --

A30: Mirror Module #5 Thermocouple 1 --

A30: Mirror Module #6 Thermocouple 1 --

A30: Mirror Module #7 Thermocouple 1 --

Interspace

Closure Plate Window Thermocouple 4 --

IOT Structure Thermocouple 4 --

A40

Motor 5 --

Limit Switch 10 --

Thermocouple 6 --

A50 Thermocouple 12 --

Bioshield Plug

BOL Thermocouple 2 --

A60

Motor 4 --

Limit Switch 8 --

Thermocouple 4 --

Port Cell

Valve Box

Limit Switch 10 --

Limit Switch 16 SIC-2

Electromagnetic Solenoid 5

Electromagnetic Solenoid 2 SIC-2

Pressure sensor 2 --

Shutter Actuation Pump 2 --

BEOC

Thermocouple 4 --

RF Matching Box 2 --

BEOC: Filter Wheel Assembly

Limit Switch 16 --

Filter Wheel Motor 6 --

Vis Camera 2 --

Linear Stage Motor 2 --

BEOC: Calibration Assembly

Thermocouple 5 --

Blackbody Source 1 --

Integrating Sphere 1 --

BEOC: Optical Bench Thermocouple 4 --

IR Camera 2 --

R el ea se d

4/

/0

R

Region UWAVS Component UWAVS Instrument QTY Safety Class

Diagnostic Hall Cubicle Area

Cubicle 2 --

RF generator 2 --

Fast controller 3 --

PLC 3 --

Motor Controller 1 --

DC power supply 6 --signal conditioning unit 1 --

Blackbody controller 1 --mTCA chassis 1 --

Master controller CPU 1 --

PSH 1 --

ea se d

4/

/0

R

2 HIGH-LEVEL HARDWARE ARCHITECTURE

The UWAVS Instrumentation and Control system has two hierarchical roles. At the higher level the UWAVS I&C system is required to serve the larger needs of the ITER plant system. As with other diagnostics, the UWAVS system will serve as an integrated node in the CODAC (Control, Data Access and Communication) network system as a designated ITER Plant System.

At the lower level the system is required to attend to the local needs of the UWAVS electro-mechanical and opto-electrical systems. This includes measurement, control, monitoring, calibration, and maintenance using various instruments to perform UWAVS operations such as active alignment, mirror cleaning etc.

Each UWAVS port has independent two full sized cubicles. One full size cubicle houses fast controller with mTCA chassis and frame grabbers for high-speed, high-performance measurement, as well as the supervisory fast controller. Second full-size cubicle contains slow controller and all the controllers for COTS (Commercial Off The Shelf) devices except for cameras. Slow controller is used to perform slow, low frequency I&C functions. Port 02 and

Port 17 differ from other ports in terms of cubicle layout. The differences are detailed in

Section 4.1 of this document. Detailed cubicle Bill of Material (BOM) (bill of material) for each port is available in Section 4.7 of this document.

R el ea se d

4/

/0

R

3 INDEPENDENT UWAVS PORT CONTROL SYSTEM (PORT 02, 08, 11, 14,17)

3.1 Control System Architecture

All UWAVS ports are identical to each other in terms of instrumentation, fast controllers, slow controller, and COTS controllers. The functional architecture of UWAVS for a single port is shown

Figure 4. Several junction boxes are used to route the signal carrying cables from port plug to the diagnostic hall. Due to Electric Feed Through (EFT) located by port plug, limited number of connections for instrumentation in bullnose are available. This, along with challenging environmental conditions due to radiation exposure and temperature has greatly influenced the instrument selection. The shutter located in the port plug is operated using valves box in port cell using pneumatic tubes.

IR cameras and Visible cameras are key detectors in UWAVS diagnostics located in BEOC. Both

IR and Visible cameras are regularly calibrated using blackbody source, and integrated sphere respectively, which are also located in BEOC. IR cameras and blackbody source are cooled separately using cooling water supply to keep them functioning at rated temperatures for optimal measurement performance. Several of the optics in BEOC are fitted with thermocouples to monitor temperature effects. Each visible camera is mounted on linear stage motor to perform some of the calibration procedures.

Diagnostic hall houses fast controllers, slow controllers, COTS devices, master controller, network switches, and Plant System Host (PSH). Signals from different parts of the UWAVS port, DSM

(diagnostic shield module), IOT (Interspace Optical Tube System), BOL (Bio-shield Optical

Labyrinth), BEOC are routed to the diagnostic hall where controllers run I&C algorithms and software to perform measurement, control, and monitoring functions. The detailed hardware architecture laid out in [23].

R el ea se d

4/

/0

R

Figure 4. Top level architecture representative of port 14 el ea se d

4/

/0

R

3.1.1 DFW

This region contains A10 assembly that has mirror cleaning assembly, shutter system, transmission monitoring source used for transmission monitoring, and thermocouple on the aperture. The mirror cleaning assembly requires RF (Radio Frequency) power delivered to clean the mirrors via tuning stub attached to each mirror. The power carrying cables are chosen to be compatible with RF and radiation exposure requirements. The shutter is actuated using valve box located in the port cell using pneumatic tubes routed from port cell to the shutter within bullnose.

Power for calibration source is routed from diagnostic hall to the bullnose as well. All the cables are eventually routed through the EFT).

3.1.2 DSM

This region houses several mirrors in A20 module and A30 module. The mirrors are outfitted with thermocouples that are routed to the slow controller in diagnostic hall.

3.1.3 (IOT)

This region has A40 assembly, A50 Assembly. A40 assembly are the components in the IOT associated with the active alignment system, including the stepper motors, limit switches, and thermocouples. The signals for these components are routed to the control cubicle CU-7302

(port 14) through cable trays. A50 assembly mirrors are thermocouples.

The A40 mirrors within the IOT are mounted on the stepper motors and use limit switches for homing and troubleshooting. UWAVS I&C also sends high wattage power to instruments located in DSM and BEOC as represented by color orange. Stepper motors, limit switches, and thermocouples are routed via cable trays, junction boxes, and connectors to the diagnostic hall.

3.1.4 Bioshield (BOL)

This region houses two large mirrors in A60 module. Each mirror is controlled by 2 stepper motors to allow occasional alignment adjustment during maintenance periods. The Signals are routed through cable trays to the diagnostic hall.

3.1.5 (BEOC)

BEOC region contains several instruments and equipment. Notably, it has two IR cameras, and two visible cameras crucial to UWAVS measurements. The power supplies to all the cameras are routed through diagnostic hall to the BEOC, and are regularly calibrated using blackbody source, and integrated sphere respectively, which are also located in BEOC and controlled by equipment in diagnostic hall. IR cameras and blackbody source are cooled separately using cooling water supply to keep them functioning at rated temperatures for optimal measurement performance.

R el ea se d

4/

/0

R

Several of the optics in BEOC are fitted with thermocouples to monitor temperature effects. Each visible camera is mounted on linear stage to motor to perform some of the calibration procedures.

RF Active matchers are tuned by controller in diagnostic halls and receive RF power from RF generators in diagnostic hall. RF matching units dissipate large power. The details of power requirements and dissipation are in Section 4.2. There are two filter wheel assemblies, each having three filter wheels and stepper motors for filter selection. Several of the optics are outfitted with thermocouples. The detailed instrumentation in BEOC is shown in Figure 5.

Figure 5. BEOC instrumentation and BEOC calibration sources location ea se d

4/

/0

R

3.1.6 Gallery

This region has north-east shielded corner that also houses the cubicles. The motor controllers, and camera power supplies for Port 02 and Port 17 are co-located in the cubicle in the north-east shielded corner. The two ports would be sharing this cubicle with other diagnostics such as NEX0.

Please refer to cubicle layout in Section 4.1 for more details.

3.1.7 Cubicles in Diagnostic Hall

There are two full sized cubicles assigned to each UWAVS port with primary control function and gateway to the CODAC networks. The cubicle 7302 contains the Fast Controller with mTCA chassis, frame grabbers plus modules for the high-performance measurement and data acquisition. There is also a supervisory fast controller which serves as the supervisor for control system through communications with the PSH over the Plant Operations Network (PON).

The cubicle 7301 houses the slow controller, master controller, and all other COTS controllers such as motors drivers, controllers for calibration devices, RF generator, and power supplies.

The fast controller requires all four ITER network interfaces (PON, DAN, SDN, and TCN). The controller is linked to the mTCA chassis using the Multisystem Extension Interface (MXI) interface hardware described in the PCDH. The real-time measurement to the SDN and the data streaming to the DAN are accomplished using this system.

Valve box that actuates the shutters is located in port cell. Valve box contains pneumatic actuators and pumps that are routed to the shutter for pneumatic actuation. Shutter control system is elaborated in Section 3.5.

3.2 UWAVS Port Subsystem Design

Each of the UWAVS port is divided into six subsystems based on the control strategy and associated mechanical components. There is some overlap of components and functionality of these subsystems. The subsystems are further broken down into sections that show control functions and instrumentation associated with it. Typical UWAVS port with its subsystem is shown in Figure 6.

R el ea se d

4/

/0

R

Figure 6. 55.GA design breakdown into sub systems.

Beam Steering Sub System – The beam steering subsystem is comprised of active and passive components. The beam from tokamak is steered to the cameras located in BEOC via combination of fixed dogleg mirrors, and motor-controlled mirrors in A40 assembly and A60 assembly. The mirrors in A60 assembly are aligned only occasionally (as needed basis) during maintenance period, via operator visual/manual input. Mirrors in A40 assembly are used to perform active alignment during normal operations and are controlled using motors drivers and software algorithms. This process is described in following Section 3.2.1.

3.2.1 Active Alignment

55.GA performance is dependent on the accuracy and range of the field of view. Active alignment is designed to compensate the thermal displacement between the vacuum vessel and tokamak building and is achieved by instrumenting and controlling the A40 mirrors in IOT subsystem located in the interspace. Beam is steered from vacuum vessel to the cameras located in the port cell using the combination of motorized mirrors, and dogleg mirrors. Detailed mechanical description is provided in [19].

All the instrumentation for active alignment is controlled and monitored by UWAVS slow controller located in the diagnostic hall cubicle CU-7302. There are no external interfaces for this subsystem.

Special Design Considerations - The stepper motors, signal carrying cables, temperature sensors placed in interspace and port cell are subject to very high temperatures and radiation exposure. Therefore, all instrumentation in interspace needs to be radiation hardened and to ITER specifications for the instrumentation materials. A40 mirrors compensate for vessel deformation

R el ea se d

4/

/0

R by using 2 rotational actuators on A40-M1 mirror and 2 rotational actuators and piston on A40-M2 mirror. Combined these actuators allow control of position, pointing, and focus. In addition, each visible camera is mounted on linear stage to compensate difference between visible and IR camera images. Images captured on visible and IR cameras during alignment along with a tokamak model are used to provide feedback to the A40 mirror motors. Please refer to UWAVS optical model results for detailed alignment plan [24].

3.2.1.1 Control Strategy & Operational Scenarios

Initial positions of the A40 motors at various temperatures are recorded at the time of FQT

(Factory Qualification Test), and System Commissioning Test by manually aligning the imaging system to known object fiducials in the inv-vessel imaging plane. This look-up table of [motor positions, VV Temp] is used as a reference for active alignment during normal plasma operations.

Different temperatures at which this procedure is done are shown in Table 3

Table 3: Stepper Motor ‘Pre-Set’ Positions Based on Temperature

Pre-Set' Positions for Motors Temperature Structure Associated with temperature

A40-M1-Motor-1-Pos

20 Deg C IOT, Port Cell

A40-M1-Motor-2-Pos

A40-M2-Motor-1-Pos

A40-M2-Motor-2-Pos

A40-M2-Motor-2-Pos

A40-M1-Motor-1-Pos

52 Deg C IOT, Port Cell

A40-M1-Motor-2-Pos

A40-M2-Motor-1-Pos

A40-M2-Motor-2-Pos

A40-M2-Motor-2-Pos

VIS-1-Linear Stage-Pos 20 Deg C BEOC

VIS-2-Linear Stage-Pos

Normal Operations - During normal plasma operations, the A40 mirrors are commanded to

‘Pre-Set’ positions based on the temperature of IOT and Port Cell. In the Fast Controller, IR cameras and Visible cameras capture images at ‘Pre-Set’ positions to determine current view of the Tokamak matches expected view based on tokamak model and pixel-to-wall mapping

R el ea se d

4/

/0

R calibration. If there is a matching error, a software algorithm is used to find new A40 mirror assembly position to correct the optical alignment.

Fast controllers and frame grabbers housed in cubicle-7302 in diagnostic hall use captured images and the reference tokamak model to calculate the ‘offset’ that predicts how much A40 mirror motors would need to be adjusted to achieve good alignment. This ‘Corrected Offset’ is communicated to ‘Motor Controller’ over PON network. The motor controllers command the stepper motors on A40 M1 and A40 M2 mirrors over radiation hardened cables. This feedback loop with images captured on IR and Visible cameras is used to actively control A40 mirror assembly to maintain an optimal alignment.

As the temperature of vessel changes during bake out and plasma operation, A40 mirrors can maintain the alignment by using the feedback loop with images captured on cameras. If the active alignment fails and images captured are not correct representation to tokamak surface locations, A40 mirrors are commanded to ‘Pre-Set’ position based on the present temperature of the vessel.

After software algorithms confirm the optimal alignment at ‘Pre-Set’ positions, active alignment is resumed.

The active alignment is a low frequency alignment. The signal chain for active alignment is shown in Figure 7.

R el ea se d

4/

/0

R

Figure 7: Active alignment signal chain el ea se d

4/

/0

R

UWAVS Instrumentation and Control Architecture 304243-R00030/B

3.2.2 Active Alignment Components

The basic components of active alignment are shown in Figure 8. Portion (a) shows stepper motors mounted on the A40 mirrors M1 and M2. Each stepper motor has 2 limit switches for position sensing. The stepper motors are controlled using the motor drivers located in the diagnostic hall. The limit switches are monitored using slow controller. Portion (b) shows that mirror M2 has three stepper motors, and mirror M1 has two stepper motors. Together M1 and M1 provide five degrees of freedom to perform active alignment. The mirrors M1 and M2 are outfitted with 3 thermocouples each to measure the temperature gradient across the mirror to understand mirror deformation. A single motor controller will be used per port to control the A40 mirror motors.

The motor controller can micro-step the stepper motors if needed.

Figure 8. Active alignment system (a) Components (b) detailed instrumentation on A40 mirrors ea se d

4/

/0

R

The mechanical design with steppers mounted on mirror is shown in Figure 9.

Figure 9. A40-M2 mirror subassembly physical architecture. Mirror (a) normal, (b) side, and

(c) rear isometric views. Some components transparent for clarity.

3.2.3 Stepper Motors

Standard NEMA-17 size stepper motors will be used throughout the UWAVS system. Where needed, radiation-tolerant stepper motors from Empire Magnetics will be used (model RH-U15-2).

Figure 10. Photos of a typical UWAVS mirror mount and radiation-hardened stepper motor.

The stepper motors have the advantage that they can be reliably operated in open-loop, an important requirement as it avoids the need for radiation-sensitive encoder electronics.

R el ea se d

4/

/0

R

Note: It has yet to be confirmed that the stepper motors can be used in the interspace due to the high magnetic fields. This is under investigation and will be resolved during FDR.

3.2.4 Rad-hard Limit Switches

The mechanical design calls for each mirror axis having limit switches to serve as a home reference and end of travel detection. Radiation hardened limit switches will be used on mechanical stages in the Port Cell. A candidate switch is ALLECTRA 363-SWITCH-RAD1 that is used on multiple ITER diagnostic designs, including 55.G1.

Figure 11. Photos of a typical UWAVS mirror mount and radiation-hardened stepper motor.

Two potential miniature switch candidates are from Crouzet are shown below. These will be pursued during final design.

Figure 12. Rad-resistant miniature limit switch from Crouzet el ea se d

4/

/0

R

Note: The limit switches are useful for moving the mirrors to repeatable positions. However, in practice all adjustments will be relative after initial alignment during system commissioning.

Therefor the limit switches can be considered useful but non-essential in failure.

3.2.5 Stepper Motor Controller/Driver

The step motors will be controlled and driven using modular system from Physik Insrumente PI

885 R2 chassis equipped with a PI 888.M1 Processor module and twenty model C663.12C885

Mercury Step Stepper Motor Controller Modules. The chassis will be powered using an external

24V power supply.

This controller has several benefits including native Experimental Physics and Industrial Control

System (EPICS) support and the fact that it is also being adopted by the 55.G1 system. This system is considered COTS requiring integration discussed in Section 3.7

One issue that needs to be tested is the ability of the driver cards to drive the step motors over

100m or more of cable.

C-885.R2 19" Card RackC-885.M1 Control CardC-663 Step Drive Cards

Figure 13. Stepper Motor Control system components from Physik Instrumente ea se d

4/

/0

R

Table 4. Active Alignment I&C Components per Port

Device Manufacturer Number/

ITER Part Number

QTY

Rad-hard Stepper Motors Model RH-U17-2 5

Rad-hard Limit Switches Model 363-SWITCH-RAD1 10

3U Motor Controller Chassis PI C885.RD 1

Motor Controller Card PI C-663.12C885 5

Modular DC Power Supply Chassis Keysight N6700 Controller 1

DC Power Supply Module Keysight N6700 Module 1

3.3 Calibration Strategy

This section deals with the I&C instrumentation and approach for the calibration strategy for

55.GA in the visible and infrared range. Initial calibration of the BEOC is done during Factory

Qualification Testing, final calibration is done after installation as the final step of commissioning, see UWAVS Calibration Plan [25] for a detailed description. Many calibration values and parameters are noted during this to applied in overall calibration of IR cameras and Visible cameras during normal plasma operations. For robust system response, in-situ calibration is necessary to compensate for deteriorating optics and instrument response. Changes in the response of the instrument during operation include overall transmission due to mirror degradation, camera sensitivity, camera, and optics temperature changes.

The main goal of calibration is to convert the raw signal from the output of the detector to measurable quantity using corrections for different effects occurring in the system. Some of the requirements and complexity for IR calibration and Visible calibration differ in some respects. IR calibration is more sensitive to transmission in optical line, emissivity of the surface, and detector and optics response.

This section has a brief description of the calibration procedure and the instrumentation or signal conditioning used for that particular calibration. The 55.GA calibration approach is supported by implementing four different types of verifications, Front to end calibration

Transmission Monitoring

Back-end calibration

Verification of algorithms and external data

R el ea se d

4/

/0

R

Overall calibration, requirements, and performance measurement is topic for optical system engineering and hence scientific details and rationalization of each calibration method required by [25]. Step-by-step I&C process flow for calibration methods are shown in [23]. Different types of calibration that I&C will be participating in are shown in the Table 5.

Table 5. I&C Summary of IR and VIS Calibration

Calibration Means

IR

Camera

VIS

camera Algorithms/

Software Model

Calibration COTS device

Camera calibration using internal camera shutter

X X IR camera, VIS camera, Fast controllers

Calibration using BEOC source

X X Blackbody source controller, Integrated sphere controller

Transmission monitoring

X X DC Power Supply, filament

Image mapping X X X

Temperature conversion

X X X

Emissivity map X X X

Spectral Correction X X

Overview of calibration for UWAVS is shown in Figure 14 below. It shows, there are many types of calibration procedures and parameters applied after the raw image is captured by IR cameras and visible cameras located in the BEOC. The IR and Visible cameras are configured (integration time, filter wheel positions, etc.) for required measurement at the beginning of calibration process.

The corrections related to detector and light are types of calibrations performed on regular basis during short term maintenance and updated in software. There are calibration procedures performed during factory acceptance test such as back end calibration that gives calibration values for flat field and spectral correction, detector data processing, and background subtraction.

Other procedures such as transmission monitoring are performed in-situ regularly to determine loss of light caused in transmission line due to wear and tear of optics because of normal operations.

Temperature conversion, image mapping are calibration related to converting radiation or pixel to a measurable quantity required by UWAVS diagnostics. These calibrations involve software algorithms, look-up tables, and 3D tokamak model.

R el ea se d

4/

/0

R

Figure 14. Different types of Calibrations during UWAVS measurement.

ea se d

4/

/0

R

3.3.1 Camera Calibration

IR camera calibration using internal shutter gives non-uniformity correction (NUC). The NUC compensates for radiation produced by internal components and optics of the camera. This is important step to perform accurate measurement. During the process, the IR camera shutter is closed while IR camera calibrates against itself. This calibration is repeated for different integration times to account for non-linear response of the detector for different integration times.

IR cameras fitted with thermocouples and are cooled using chiller water supply to keep them at optimal temperature.

Similar procedure is done for visible cameras to measure dark current as part of calibration process. When Visible camera internal shutter is closed, camera captures dark field images. This is repeated for different integration times.

IR cameras and Visible cameras are calibrated at end of normal operations during short term maintenance period (STM). Operator will use these calibration procedures to capture NUC, and dark current values and update them in the 55.GA software and CODAC configurations using

PON network. A detailed I&C flow for calibration procedure is provided in [23].

3.3.2 Calibration Using BEOC Sources

Camera images require to establish the relationship between digital output of the camera and temperature or luminance. This is achieved by using calibration sources, blackbody source for IR camera and integration sphere with white light source for visible camera. The calibration sources are physically located in BEOC structure, providing the nomenclature BEOC calibration sources.

Blackbody source is configured using oven controller which provides different set point temperatures. Radiation emitted by blackbody at different set points is captured by IR cameras for different integration times. This gives a lookup table values for each integration time.

Each visible camera has a set of filter wheels. Integrated sphere with white light source is used in similar manner to perform calibration process and obtain look-up tables for luminance for each integration time using the visible cameras. This process repeated for different filters. Detailed I&C operation procedures for these calibrations are provided in [23]. Detailed filter wheel assembly is described in Section 3.6.7.

It takes ~ 80 mins for blackbody source to warm up and reach stable temperature. Integrated sphere takes ~ 5 mins to reach reference luminance. Calibration using BEOC sources is thought be done minimum once a year, with ability to perform it during short term maintenance (STM) if needed.

R el ea se d

4/

/0

R

The Figure 15 shows physical location of blackbody source and integrated sphere in BEOC with respect to IR camera and visible camera.

Figure 15. BEOC calibration source location with respect to cameras

3.3.2.1 BEOC Sources & Components

The BEOC contains two light sources: A Blackbody source for the IR cameras and white LED based fixed luminance sphere for the visible cameras.

Figure 16. Picture of the Model 458-4 LED-Standard Lamp with Integrating Sphere

The luminance sphere selected is an Optronics Laboratories model OL 458-4 NIST-traceable source shown in Figure 16. The OL 458-4 consists of an optics head and an external power

R el ea se d

4/

/0

R supply. Internal to the head is the OL 458-4 has an integrated constant current supply to provide luminance stability. The head will be simply controlled by powering the device from a switchable

48VDC power supply in the diagnostic hall. While the head provides a USB interface for optional remote control, this feature will be disabled, and any associated electronics removed.

The blackbody source is a more complicated device as it utilizes a high-temperature furnace that must be precisely temperature regulated. The source selected is an Advanced Energy model

M330 (Figure 17) with some customization and modification including separating some electronics and re-packaging the furnace.

Figure 17. Model M330 Blackbody Source (shown without customization)

There are several advantages to re-packaging the device. First, the unit is built into a standard

19” rack enclosure that is not suitable for the ITER Port Cell environment and is awkward to integrate into the BEOC. Fortunately, the modular construction of the unit facilitates separation of the furnace assembly, power transformer, and controller for better hardening (Figure 18). Second, the controller is a standard COTS Eurotherm temperature controller that will be remotely located in the diagnostic hall by using a thermocouple transmitter recommended by the vendor (Advanced

Energy).

R el ea se d

4/

/0

R

Figure 18. Inside of the enclosed Model M330 Blackbody Source. The internal assemblies will be removed from the enclosure for integration directly in the BEOC. The controller will be located in the diagnostic hall.

3.3.2.2 BEOC Sources BOM

The I&C components used for the BEOC calibration are listed in Table 6 below. Note that the

Keysight Modular DC Power supply is shared with other systems.

Table 6. BEOC Calibration BOM

Device Manufacturer Number/

ITER Part Number

Black Body Source Advanced Energy M330

Visible Source Optronics Laboratories OL 458-4

Modular DC Power Supply Chassis Keysight N6700 Controller

DC Power Supply Modules Keysight N6700 Modules

R el ea se d

4/

/0

R

3.3.3 Transmission Monitoring

Transmission monitoring is used in 55.GA to assess the loss of light in optics due to wear and tear of optical components and general aging of the 55.GA system. Transmission changes in IR and Visible spectrum over lifetime of 55.GA include mirror coating degradation and deposition of foreign objects or debris on the first mirrors. This impacts the accuracy of measurement done by detectors (IR and VIS cameras) because less light is reaching the cameras causing inaccurate surface temperature measurement by IR cameras. Therefore, it is important to perform a procedure for monitoring and correcting the transmission change. For this purpose, 55.GA uses a filament attached to a shutter in bullnose as a transmission monitoring source. The filament can be heated from range of 400 deg c to 1500 deg c allowing both IR cameras (~400 deg c range) and Visible cameras (~1500 deg c) to monitor transmission changes in their respective bands.

To perform Transmission Monitoring, a shutter is closed, and DC power is sent to the heated filament located on the shutter. Voltage received at heated filament is read to calculate power deposited and calculate referred temperature of the filament. After the filament is heated to a certain temperature set point and is stable, IR cameras and Visible cameras acquire images. This process is repeated for defined set of integration times and gains.

The images acquired by IR and Visible cameras are compared to the previous data to calculate the ‘delta’ image that shows degradation in transmission of light since last transmission monitoring was performed. Mirror temperatures and other optics temperatures in 55.GA system are acquired during the process and need to be used as calibration factor for the images. The ‘delta’ images are used to calculate the transmission monitoring co-efficient and is updated in the 55.GA system and CODAC via PON network. All the images captured during transmission monitoring procedure, including ‘delta’ images are streamed on DAN network to CODAC. Detailed I&C flow is documented in [23].

Transmission monitoring is performed at the end of every normal plasma operation (as needed) and during the short-term maintenance (STM).

R el ea se d

4/

/0

R

3.3.3.1 Transmission Monitoring Components

Figure 19. Transmission monitoring filament control scheme

The UWAVS system uses a heated source mounted on the shutter (in the bullnose) to monitor changes in optical transmission and provide correction factors. The heater is a single assembly containing two filaments. Each of the two filaments is driven and measured using separate circuits. The transmission monitoring process relies on accurate measurement of the electrical power delivered to the filament which in turn depends on the current through the filament IF and the voltage across the filament VF:

Power = IFVF

The filaments are driven using a programmable DC power supply remotely located in the diagnostic hall cubicle, so large voltage drops are expected due the high current (10-20A) and long wires (around 100m). Therefore, a Kelvin-type 4-wire measurement scheme is used to drive a precise current while accurately measuring the voltage across the filament.

A diagram is of the measurement is shown in Figure 19. One pair of wires is used to drive a precise current through the filament. A second pair of wires (carrying no current) is used to measure the potential difference across the filament. A 16-bit Analog Input (AI) channel on the

PLC (programmable slow controller) slow controller is used to monitor the voltage with sufficient precision. The signals are filtered using a custom module to remove noise including potential

Radio Frequency (RF) pick-up.

The exact current, voltage, and power will depend on filament construction which are currently in development. Anticipated range for power is 75-100W, with currents ranging from 10-20A and

R el ea se d

4/

/0

R voltage between 5 and 15V. Estimated precision in power measurement is 0.14% based on experience.

In order to use absorbed electrical power for calibration it is important to understand potential changes in filament emissivity with age. Prototyping and testing are essential to validate technique and is planned during final design.

3.3.3.2 Transmission Monitoring BOM

The I&C components used for the transmission monitoring are listed in Table 7 below. Note that the Keysight Modular DC Power supply is shared with other systems, and the Siemens PLC listed is the Plant System Slow Controller.

Table 7. Transmission Monitoring BOM

Device Manufacturer Number/

ITER Part Number

Filament Under design

PLC Slow Controller

SM531-8AI /

6ES7531-…