Attachment (B3) NSLSII-CRL-RSI-001_v4.pdf

NSLSII-CRL-RSI-001

Experimental Facilities

Requirements, Specifications and Interfaces for the Controls and Data Acquisition System

Version 4

April 7th, 2023

Concurrence and Approval Signatures:

Andrew Broadbent Partner Beamline Portfolio Manager

Stuart Wilkins DSSI Program Manager

Zhijian Yin Motion Controls Group Leader

Nathanael Maytan Beamline EPS Engineer

Anton Derbenev DSSI Group Leader

The NSLS-II Experimental Facilities Requirements, Specifications and Interfaces for the Controls and DAQ

Systems is a controlled document, revised under change control.

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Version History Log

Version

Number Date Author(s) Reviewers Changes made

1 May 13, 2011 Wayne Lewis

Andy Broadbent

Daron Chabot

First version ready for release

2 April 4, 2012 Wayne Lewis Updates include:

Encoder alarm indication and clock frequency specification. (Section g)

Digital camera manufacturer and model clarification. (Section 2.9)

Analog camera interface requirement. (Section 2.9)

Piezo controller requirement (Section b) (Section added in Rev 2. Change Log updated in Rev 3.)

3 April 9, 2013 Wayne Lewis Update PLC models (Section 2.5)

Clarified analog camera format (Section 2.9)

Include Manta cameras (Section 1.1b)

Minor wording updates for clarity (Sections b, c, Error! Reference source not found.)

Allow wider range of stepper motor step counts (Section d)

Allow motor controller to power active limit switch (Section f)

Added power supply requirements (Section 1.13)

Remove SSI absolute protocol (Section f)

Updated approval signatures (Removed project beamline group leaders, remove controls engineers, added ABBIX and NEXT beamlines group leaders)

4 April 7, 2023 Andrew Broadbent

Julian A.

Lonny B.

Jeff K.

Erik J.

Paul Z.

Evgeny N.

Stephen H.

Updated document number from LT-C-XFD-RSI-CO-001 to the current format in accordance with NSLSII-DPT-PDN-001, Management of NSLS-II Documents and Records. Updated all references in Table 1 (Section 1.2); deleted Table 3 (PLC IO module list); emphasized preference for using direct termination to remote IO modules (Section 2.5Error! Reference source not found.); added requirement for position reference (Section 2.1.7 a); added prevention of hard stop contact to requirement for overtravel, added switches (Section 1.12.2);

updated IOC hardware specification (Section 0.1 a); added Power over ethernet requirement for digital cameras (Section 2.9e); modified VDCT requirement (Section 0.2 a); added details for absolute encoders (Section 2.1.2 h, i, j, k);

updated USB requirement (Section 2.4c); changed 'shall be approved by BSA' to 'requires approval by BSA'; updated EPICS Base version (Section 1.4.1);

updated synApps version (Section 1.4.3); added direction requirement for absolute encoder scale (Section 2.1.2 m). Made major changes to all sections to bring the document into line with current practice.

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Contents

1 Overview and General Control System Requirements

1.1 Overview

1.2 References

1.3 Introduction

1.4 EPICS Software Versions

1.5 EPICS Support

1.6 BSA-Supplied Items

1.7 Operator Interface (OPI)

1.8 Software Development

1.9 Other Software

1.10 Naming

1.11 Computer and Electronic Hardware

1.12 Equipment Protection

1.13 Power Supplies

2 Control System Interface Definitions

2.1 Motion Control

2.2 Piezo Actuators

2.3 Controls Network

2.4 Serial Devices

2.5 PLC

2.6 Digital IO

2.7 Analog IO

2.8 Triggers

2.9 Cameras

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Acronyms and Abbreviations

BL Beamline

BNL Brookhaven National Laboratory

BOY Best OPI Yet

BSA Brookhaven Science Associates

CED Cost Estimate Database

CSS Control System Studio

DAQ Data Acquisition dBA deciBel (A weighted)

DHCP Dynamic Host Configuration Protocol

EAHJ Electrical Authority Having Jurisdiction

EDM Extensible Display Manager

EEI Electrical Equipment Inspection

EPICS Experimental Physics and Industrial Control System

EPS Equipment Protection System

ESA Electrical Safety Advisor

Gb Gigabit

GB Gigabyte

GNU GNU's Not Unix

GUI Graphical User Interface

IOC Input/Output Controller

LESO Laboratory Electrical Safety Officer

NRTL Nationally Recognized Testing Laboratory

NSLS-II National Synchrotron Light Source II

NTSC National Television Standards Committee

OPI Operator Interface

PC Personal Computer

PLC Programmable Logic Controller

PV Process Variable

RHEL Red Hat Enterprise Linux

RSI Requirements, Specifications, and Interfaces

RTEMS Real-Time Executive for Multiprocessor Systems

SOW Statement of Work

TTL Transistor-Transistor Logic

USB Universal Serial Bus

VDCT Visual Database Configuration Tool

VME VERSA Module Eurocard

WBS Work Breakdown Structure

XFD Experimental Facilities Division

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1 OVERVIEW AND GENERAL CONTROL SYSTEM REQUIREMENTS

1.1 Overview

This document, National Synchrotron Light Source II (NSLS-II) Experimental Facilities (XFD) Requirements, Specifications and Interfaces (RSI) for the Controls and Data Acquisition (DAQ) Systems, is a part of the documentation system and maps to the NSLS-II project Work Breakdown Structure (WBS) and Cost Estimate

Database (CED).

It captures and summarizes all the general requirements and specifications for the WBS elements within 1.04.02, Standard Local controls and Data Acquisition Systems, and describes all its technical interfaces with other WBS elements. Note that many individual pieces of equipment will carry their own controls or DAQ requirements that will be documented within individual RSI and/or statement of work (SOW) documents.

1.2 References

Table 1: References.

Identification number or code Title

NSLSII-DPT-STD-002 NSLS-II Nomenclature Standard

NSLSII-CRL-STD-001 NSLS-II Beamline Systems Instrumentation Interfacing Standard

NSLSII-CRL-STD-002 NSLS-II Beamline Coordinate System Design Standard

1.3 Introduction

1.3.1 BSA has selected the EPICS control system tool kit for the distributed control system for the NSLS-

II accelerators, beamlines, and conventional facilities. The motor control system, vacuum control system and interface to the diagnostic components shall be based on this standard to enable cost effective and seamless integration with the rest of the facilities at NSLS-II.

1.3.2 Further information on EPICS can be found at https://epics-controls.org/.

1.3.3 The EPICS clients shall be PCs running Red Hat Enterprise Linux Ver 8 (RHEL 8).

1.3.4 EPICS servers on PC hardware shall run the current version of RHEL.

1.4 EPICS Software Versions

1.4.1 All EPICS software submitted by the Contractors, Collaborators or any other third party shall be based on EPICS base version R7.0.5 (or later version as specified by BSA).

1.4.2 Where additional EPICS modules are used, the versions shall be according to Table 2 (next page).

Later versions may be specified by BSA.

1.4.3 If a module is not explicitly specified in Table 2, the default version of this module used shall be the version provided in the corresponding EPICS collaboration repository. The module shall build with

EPICS base and modules of versions specified above.

https://epics-controls.org/

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Table 2: EPICS Module Versions.

Module name Version areaDetector 3-10 asyn 4-41 autosave 5-10-2 busy 1-7-3 calc 3-7-3 modbus 3-2 motor 7-2-2

SNCSEQ 2.2.0

std 3-6-2 stream 2-8-10 etherIP 3-3 adsDriver 3.0.0

1.5 EPICS Support

Where the contract involves the development of an EPICS interface to the components, sections 1.5.1 through

1.5.3 shall apply.

1.5.1 IOC platform

a. The current standard NSLS-II IOC hardware platform is the HPE DL360 series. BSA will confirm the details of the IOC hardware specification prior to the purchase of the IOC.

The 2022 standard is;

• DL360 Gen 10, Xeon S4210

• 128 GB RAM, 2 x 1.2 TB SSD

• 10 GbE 2p SFP + NIC + transceiver

b. All IOC hardware shall be installed into the standard 19-in. rack by the Contractor. Desktop workstations may be allowed under certain circumstances when approved in writing by BSA.

c. The IOC shall be included in the system performance tests at the Supplier’s factory.

1.5.2 Database development

a. Where layout information is included in the database file, it shall be compatible with the current version of the VDCT EPICS database development tool.

1.5.3 Device support

a. The Contractor shall supply EPICS device drivers and device support for any hardware delivered as part of this contract.

b. Where the Contractor provides a motion controller, the EPICS interface shall be the standard

Motor record (Table 2), or a set of records that provides equivalent functionality.

c. EPICS device drivers, libraries, binaries, etc., hardware support code shall build with EPICS base and modules described in Section 1.4.

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1.6 BSA-Supplied Items

BSA will provide the following items to the Contractor:

a. Control System Studio (CSS) (NSLS-II distribution), upon request.

b. 19-inch equipment rack cabinets for mounting the control system components at NSLS-II.

c. A graphical user interface (GUI) style guide, available upon request, on contract award.

d. A naming convention document for the instrumentation and control system (refer to Table 1).

e. Build tools to create the NSLS-II standard EPICS RPM package (includes base and baseline modules).

f. A specification for the file structure to be used for EPICS software development. This specification can be found at https://docs.epics-controls.org/en/latest/specs/EPICSBuildFacility.html#overview.

1.7 Operator Interface (OPI)

Where the contract involves the development of an EPICS graphical user interface to the components, the following shall apply.

1.7.1 The Contractor shall supply a GUI to perform the following functions:

a. Equipment control panel(s) showing the state of all signals associated with the equipment.

These should enable users to monitor and control the equipment for routine operation. It shall be possible to call up the engineering control panels from the Equipment panel.

b. The engineering control panels should enable engineers to monitor and control all the available parameters of the equipment for commissioning and for troubleshooting.

1.7.2 The Operator Interface (OPI) shall be implemented using CS-Studio (Phoebus) Display Builder.

1.7.3 The version of CS-Studio (Phoebus) used shall be NSLS-II release 4.7.1 or later version as approved by BSA.

1.7.4 The operator interface shall be implemented on a Linux PC. The version of Linux used shall be as defined in 1.3.3 for client machines.

1.7.5 The operator interface shall be designed in accordance with the GUI style guide referred to in 1.6.f.

1.7.6 The OPI for all optical elements shall include information about the direction and sign of the coordinate system used, including linear and rotation axes.

1.8 Software Development

1.8.1 The Contractor shall provide current versions of all source code developed by the Contractor when the relevant Equipment is delivered to the Purchaser.

1.8.2 The Contractor shall provide final versions of all source code developed by the Contractor at the completion of equipment commissioning.

1.8.3 The Contractor shall provide software design documentation including functional specifications, sequence diagrams, class diagrams etc. for the software developed to meet this contract.

1.8.4 A suitable level of commenting shall be adopted for all developed software. As an indication, comments should be provided, on average, for every subroutine and any complex code segment.

1.8.5 The software documentation shall include instruction on how to build, install and operate the software.

1.8.6 All software comments shall be in English.

1.8.7 The Contractor shall allow the source code developed to meet this contract to be open source, consistent with the 3-Clause BSD License.

https://docs.epics-controls.org/en/latest/specs/EPICSBuildFacility.html#overview https://opensource.org/licenses/BSD-3-Clause

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1.8.8 If Python code is incorporated by the contractor, it shall support a version of Python that will not reach end-of-life for at least two years from the delivery date, as specified in https://devguide.python.org/versions/.

1.9 Other Software

1.9.1 The Contractor shall provide EPICS device support source code for all devices supplied as part of this contract.

1.9.2 EPICS IOCs which are provided by the Contractor shall indicate that a given operation is "complete" by implementing write-with-callback (i.e., put-completion) on the writable PV.

1.10 Naming

1.10.1 All devices and database records shall be named in accordance with the NSLS-II Nomenclature

Standard, NSLSII-DPT-STD-002.

1.10.2 Where the existing NSLS-II Nomenclature Standard does not provide the names required, the names shall be developed in consultation with BSA. The Contractor shall receive approval, in writing, from

BSA for all names prior to final delivery of the devices and databases.

1.11 Computer and Electronic Hardware

1.11.1 Electrical energy consumption of rack-mounted hardware (e.g., PCs, IOCs and motor controllers) should be minimized where reasonably possible.

1.11.2 Electrical energy consumption of desk-mounted equipment (computers, monitors, etc.) should minimize the heat dissipated to the air.

1.11.3 Acoustical noise generation by desk-mounted equipment should be minimized. A suggested maximum Sound Pressure Level (SPL) from each component, when operating, is 40 dBA, measured at 1 m.

1.11.4 All rack-mounted equipment shall draw air from the front of the equipment and exhaust to the rear.

The NSLS-II equipment racks are actively cooled, with cool air provided at the front of the rack and warm air removed from the back of the rack.

1.12 Equipment Protection

1.12.1 General

a. All equipment protection instrumentation and logic shall be designed to be fail safe.

Circumstances to be considered include, but are not limited to, electrical power failure, compressed air failure, and cable breakage.

b. All equipment provided by the Contractor should be supplied in sufficiently robust enclosures which protect from the environmental dangers of the application such as dust, dirt, spills, leaks, heat, UV, radiation, wildlife, or mechanical damage. Enclosures should be suitably IP-rated as appropriate.

c. Where the Contractor implements the equipment protection system, it shall be PLC based. PLC components shall be as defined in section 2.5.

d. Any equipment protection system(s) shall be used only to either provide information which is used to protect equipment (whether manually or by system action), or else acts to protect equipment (including by preventing dangerous operating modes). Exceptions to this restriction may be requested by the Contractor or by BSA, particularly for systems which are self-contained and handle their own protection. Any exceptions to this restriction shall require approval by

BSA.

https://devguide.python.org/versions/

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e. The Contractor shall provide documentation which describes the equipment protection requirements and any protective actions or behaviours which they have implemented. Such documentation shall be used as evidence that the protection or means to provide protection have been adequately provided. Protection requirements and fulfilment of those requirements is subject to approval by BSA.

1.12.2 Motor and Motion Protection

a. All components that have motion axes shall be protected by limit switches to prevent collision with other components or hard stops.

b. These limit switches shall be directly (i.e., through hardware) connected to the limit switch inputs of the motion controller. Where these switches must also be intercepted by the equipment protection system, relays should be used.

c. Refer to section 2.1.3 for details about limit switch configuration and specifications.

d. Where collision between two moving components is possible, proximity switches shall be provided to prevent any collision.

e. These proximity switches shall be wired in series with the relevant motion axis’ limit switches and shall be directly (i.e., through hardware) connected to the limit switch inputs of the motion controller. Where these switches must also be intercepted by the equipment protection system, relays should be used.

f. Where additional protection is required (e.g., for Health and Safety reasons, due to the high value of the equipment, or where hitting a hard stop is especially unacceptable), overtravel switches shall be provided which can be used to disable the amplifiers either by a signal to the amplifier or by actively removing the power supply to the amplifier.

g. Both proximity and overtravel switches shall adhere to the same requirements as limit switches as defined in section 2.1.3.

h. All motion controllers shall have an interface which enables the capability to electronically disable the amplifiers either by a signal to the amplifier or by actively removing the power supply to the amplifier. This requirement holds even if this capability is currently to be unused.

i. Where a motor is installed and operated under vacuum, temperature monitoring of the motor shall be provided. The Contractor shall define the safe operating range for the motor, and a mechanism must be provided which can automatically disable the associated amplifier upon an overtemperature event occurring.

j. Where operation of a motion axis may result in a harmful collision with personnel, or otherwise may create a risk of injury to personnel, additional protection mechanisms may be required. Such situations should be identified by the Contractor and addressed in accordance with BSA policy.

k. Software-based equipment protection solutions may only be used in addition to a hardware solution, as described in this section (1.12.2).

1.12.3 Heating Protection

a. All components, particularly those exposed to high heat loads, shall have sufficient instrumentation to enable monitoring of the integrity of the equipment. This instrumentation will be interfaced to an interlock system which will take action to prevent any permanent damage to the component.

b. The Contractor shall define the safe operating range for each component based on the instrumentation provided for that component. Examples include minimum water flows, maximum allowable temperatures, and locations of valid-position switches.

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c. The Contractor shall define the required interlock actions when equipment is outside the safe operating range. Examples include, close an upstream photon shutter, turn-off a temperature controller, and kill a motion controller.

d. The Contractor shall define the response time and duration required for protective action to occur.

1.12.4 Vacuum Protection

a. Instrumentation to monitor the vacuum within a vacuum-holding volume will be provided using gauge heads mounted on the volume (supplied by the Contractor) and BSA-supplied vacuum controllers.

b. The Contractor shall supply sufficient isolation capability (e.g., vacuum gate valves) around each beamline component.

c. Each vacuum section created by a vacuum isolating device shall have a vacuum monitoring instrument installed to monitor that section’s volume.

d. The Contractor shall define the required protection logic for vacuum protection, in accordance with any facility requirements as defined by BSA. These requirements should include, but are not limited to:

▪ extending the lifetime of ion pumps by ensuring they are operated under ideal vacuum,

▪ preventing the creation of ozone by sending beam through poor vacuum,

▪ preventing the scattering of radiation by sending beam through poor vacuum,

▪ preventing damage to sensitive equipment by creating a pressure differential,

▪ preventing damage to a turbo pump which would occur by running it full-speed and opening it to a volume at atmosphere.

e. Where liquid nitrogen (e.g., a cryocooler) is used to cool a load under vacuum, the Contractor shall define a permitted operating range for the vacuum section(s) which receive cooling, outside of which the supply of liquid nitrogen shall be inhibited.

f. Where the Contractor provides vacuum isolating gate valves, all gate valves which are in the path of white or pink beam shall have a second set of position indicator switches which can be integrated with the Beamline’s “White-Beam Gate Valve Circuit”.

g. The Contractor shall define the required protection logic for any vacuum isolating gate valves which they provide. This protection logic shall ensure, at minimum:

1. the valve shall not open unless sufficient vacuum is seen on either side of the valve,

2. the valve shall interlock if insufficient vacuum is observed on either side of the valve,

3. the valve shall close (but not interlock) if insufficient vacuum is observed in the next downstream vacuum section from the valve,

4. the valve shall not close until the next upstream photon shutter is closed,

5. the next upstream photon shutter from the valve shall be requested to close when the valve observes a vacuum fault,

6. the next upstream photon shutter from the valve shall be prevented from opening while the valve is not open.

h. Where the Contractor provides electrical or electronic in-vacuum devices that can only operate in certain pressure ranges, the Contractor shall define permitted operating ranges of these devices and shall provide a means of inhibiting these devices.

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1.12.5 Other Protection

a. Where a large quantity of liquid is to be utilized by a component, such as for water cooling, sufficient leak detection shall be provided and installed around the component and any associated plumbing. This leak detection will be interfaced to an interlock system which will take action to minimize the leak.

b. Where a continuous supply of liquid nitrogen is used, crash buttons shall be provided to force-close the supply in the event of an emergency. Such emergency buttons shall provide a hardware-based shut-off (i.e., by physically breaking the circuit) rather than a software-based shut-off.

These crash buttons must be easily accessible and will be monitored by an interlock system.

c. Where the equipment protection system is implemented by the Contractor, the system shall detect first faults (i.e., the direct cause of an interlock) and provide a mechanism (such as EPICS PVs) to notify the operators of the root cause.

d. Where the equipment protection system is implemented by the Contractor, the system shall enter and maintain a safe state for all components upon communication failure with any local or remote

I/O. Example: a remote I/O box is unplugged from the main PLC.

e. The requirements for equipment protection listed here are not necessarily exhaustive. Unique or specialized equipment often has its own specific protection requirements which cannot be captured generically. The Contractor shall identify these unique, specific cases and provide the appropriate protective measures to address them. Examples: independent motion collisions, detectors which can be damaged by impact.

1.13 Power Supplies

1.13.1 All equipment supplied by the Contractor shall be provided with appropriate power supplies. These power supplies shall accept a US-standard 110 VAC mains (60Hz, single phase) as input, unless shown to be insufficient for equipment requirements. Where possible, the contractor should supply universal input power supplies (85 – 264 VAC).

1.13.2 Any power supplies requiring input other than 110 or 208 VAC, or greater than 15 A, shall be explicitly identified by the Contractor and require approval by BSA.

1.13.3 Use and distribution of voltages above 32 V shall be minimized to the extent possible for the application. For example, where feasible, the 120 VAC power supply for a PLC enclosure should be kept external to the enclosure with only 24 V DC remaining inside.

1.13.4 All power supplies and power-supplying circuits (such as a power bus tap-off) shall be appropriately fused as to protect conductors against overheating or otherwise exceeding the rated current for the application. Where cartridge or other replaceable fuses are used, the Contractor shall provide an identically rated spare fuse (min quantity 1) by temporarily affixing them adjacent to the location of the fuse(s).

1.13.5 All commercial, off-the-shelf electrical equipment supplied by the Contractor, which requires an internal or external power source, whether as a standalone unit or as a component of a larger piece of equipment, shall be certified by a Nationally Recognized Testing Laboratory (NRTL). Non-

NRTL certified equipment requires approval by BSA and requires detailed documentation, review, and inspection.

1.13.6 All such equipment as described in 1.13.5 shall be subject to, and must pass, a safety inspection in accordance with requirements set by the Electrical Authority Having Jurisdiction (EAHJ). It is recommended that the Contractor communicates with the EAHJ, Laboratory Electrical Safety

Officer (LESO), Electrical Safety Advisor (ESA), or local Electrical Equipment Inspection (EEI)

Inspector early in the design process (and continually until work is completed) to ensure that all equipment meets the required electrical safety standards.

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2 CONTROL SYSTEM INTERFACE DEFINITIONS

2.1 Motion Control

This section defines the interfaces to the standard NSLS-II motion controller. In order to connect a motor to this motion controller, the components provided shall meet the following specifications.

The standard NSLS-II motion controller for stepper and servo motors is the Delta Tau Power Brick LV-IMS.

Where the Contractor is supplying the motion controller, the Contractor should use the NSLS-II Standard

Motion Controller. Use of alternative motion controllers requires approval by BSA.

2.1.1 Motors

This section defines the motor types that can be driven by the NSLS-II Standard Motion Controller internal amplifiers. For motors that do not meet these specifications, refer to section 2.1.6.

a. Stepper motors driven by the standard NSLS-II motion controller shall be two-phase bipolar.

b. Two-phase steppers should have the phases wired in parallel.

c. Two-phase steppers should have phase resistance of less than 2 ohms in the parallel wired configuration.

d. Two-phase steppers should have either 200 or 400 full steps per revolution.

e. Stepper motors shall have a continuous current rating of 5 A maximum.

f. Stepper motors shall have a rated voltage of 48 V maximum.

g. Servo motors shall have a continuous current rating of 5 A maximum.

h. Servo motors shall have a rated voltage of 48 V maximum.

i. Servo motors may be brushed or three-phase brushless.

j. Three-phase brushless servos shall provide commutation information, either through an encoder or hall effect sensors, or equivalent.

k. The motor connector pinout shall follow the definitions in the Instrumentation Interfacing

Standard document, NSLSII-CRL-STD-001.

l. Any required deviations from the above specifications require written approval by BSA.

2.1.2 Encoders

a. Incremental encoder signalling level shall be differential RS-422.

b. Encoders shall operate with a 5 V power supply.

c. Encoder pinout shall be provided as defined in NSLSII-CRL-STD-001, NSLS-II Beamline

Systems Instrumentation Interfacing Standards.

d. Where the encoder provides an index position, the signal shall be differential RS-422.

e. Incremental encoders shall indicate an alarm condition by setting the differential quadrature signals (A+, A-, B+, B-) to the same state. The Renishaw 3-state alarm format is an example of an alarm indication mode that meets this requirement.

f. Absolute encoders shall use the BiSS-C protocol. Any alternative absolute encoder protocol requires approval by BSA.

g. Incremental encoders shall have a maximum internal clock frequency of 10 MHz. Higher internal clock frequencies may only be used with BSA approval.

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h. The NSLS-II preferred encoders are the Renishaw TONiC and Renishaw Resolute series. Other manufacturers and models are acceptable provided that they meet the requirements in this document and NSLSII-CRL-STD-001, NSLS-II Beamline Systems Instrumentation Interfacing

Standard.

i. Encoder scales shall be selected taking into account the scale material compatibility with the installation environment, including vacuum and radiation compatibility.

j. Rotary absolute encoders should use the 26 bit protocol.

k. Linear absolute encoders should use the 32 bit protocol. 36 bit protocol may be used if it is required based on motion range and linear resolution.

l. Absolute encoders shall have the scale mounted so that the direction is consistent with the locally defined coordinate system.

2.1.3 Limit switches

a. Limit switches shall be normally closed and shall open to indicate that the limit has been reached.

b. Limit switches shall provide a volt-free dry contact.

c. Limit switches shall be rated to 24 VDC.

d. Where an optical, capacitance, inductance, proximity, or similar limit switch is provided, suitable electronics shall be supplied to convert the signal to one that meets the criteria in 2.1.3.a through

2.1.3.c.

e. Where an optical, capacitance, inductance, proximity, or similar limit switch is provided, the switch must fail safe in the event of a power supply failure.

f. Where an optical, capacitance, inductance, proximity, or similar limit switch is provided, the electronics may be powered by the motion controller or independently of the motion controller.

g. Where limit switches may need to be intercepted by the BL EPS to ensure safe operation (such as in the case that a motorized manipulator passes through a vacuum isolation valve), the connection point for limit switches shall be separated from the motor’s connection point. This connection shall be a male plug, preferably a D9 connector.

h. Where the limit switch connection point is separated from the motor’s connection point, a secondary connection point shall be provided for injecting limit status to the motor cable. This connection shall be a female plug, preferably a D9 connector.

i. Where the limit switch connection point is separated from the motor’s connection point, the limit switches shall be rated to withstand a small current such as to drive a small relay. This rating shall be no less than 100 mA.

2.1.4 Reference/home/datum switches

a. These switches may be either normally open or normally closed.

b. These switches shall provide a volt-free dry contact.

c. These switches shall be rated to 5 VDC or 24 VDC: 24VDC is preferred.

d. Where an optical, capacitance, inductance, proximity, or similar switch is provided, suitable electronics shall be supplied to convert the signal to one that meets the criteria in 2.1.4.b and

2.1.4.c.

e. Where an optical, capacitance, inductance, proximity, or similar switch is provided, the electronics shall be powered independently of the motion controller.

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2.1.5 Motor brakes

a. Where a motor brake is provided, it shall operate with a 24 VDC signal provided by the motor controller. The current drawn by the brake, in either the activated or deactivated state, shall not exceed 500 mA.

b. If the motor brake requires higher voltage or current than those defined in 2.6.g, the Contractor shall provide all required components to allow the brake to be activated by a signal that meets the requirements defined in 2.6.g.

c. The use of motor brakes should be minimized as far as is practicable.

2.1.6 External Motor Drives

Where a motion axis has a motor that cannot be driven by the standard motion controller, as defined in section 2.1.1, an external drive shall be provided for this axis. The motor drive shall meet the following interface specification for connection to the standard motor controller.

a. A stepper drive shall accept step and direction signals.

b. The step and direction signals shall be RS422 differential signal levels.

c. A servo drive shall accept either step and direction signals or a -10 V to +10 V analog signal.

d. All external motor drivers must be approved by BSA.

2.1.7 Reference Position

a. Every motorized motion axis shall have a reference position indicator with a resolution consistent with the axis resolution. Acceptable reference position indicators include encoder reference, precision limit switch or precision home or datum switch.

2.2 Piezo Actuators

a. The drive or controller for a piezo actuator shall accept either step and direction signals or a -10 V to +10

V analog signal.

b. Piezo actuators shall be supplied with a controller or drive system.

2.3 Controls Network

a. Network-attached devices shall be compatible with a 1 Gb/s network.

b. Network-attached devices shall operate at a minimum network speed of 100 Mb/s.

c. Network-attached devices shall obtain their network address either through static address configuration or DHCP.

d. Network-attached devices shall include a standard RJ-45 connection and SFP.

2.4 Serial Devices

a. Any device that provides a serial communications interface to the control system shall be interfaced to the control system via a terminal server. Details of the NSLS-II standard terminal server can be provided upon request.

b. The serial connection from the device to the terminal server shall be RS232 or RS485. Where there is a choice between DTE and DCE ports, the equipment should use DCE ports.

c. The use of USB to connect a device to the control system shall be avoided, as far as is practicable. Any use of USB devices shall require prior approval by BSA.

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2.5 PLC

a. Where an application requires the use of an embedded controller (such as a PLC), and there are no superseding personnel safety concerns which arise from operation of the integrated equipment, the model used shall be from the Allen-Bradley CompactLogix 5380 series. Specifically, the 5069-L306ER shall be the minimum required model. The controller model may be upgraded within this series as needed, such as to support additional I/O or provide extra program memory. Suggested upgraded part numbers include the 5069-L310ER, 5069-L320ER, etc.

b. Where an application requires the use of an embedded controller, and there are sufficient concerns about personnel safety which arise from operation of the integrated equipment, and these concerns cannot be otherwise managed or removed through design, an appropriately rated safety PLC shall be used. The preferred choice for such an application is the Compact GuardLogix 5380 series.

c. Use of an embedded controller other than as described in 2.5.a, such as from an alternative manufacturer or of a different model number and/or series, may be requested with justification by the Contractor. BSA may also make such a request where beneficial to the application, such as to satisfy specialized requirements or due to a lack of component availability.

d. Where the instrumentation or equipment to be integrated with the PLC is distributed throughout the beamline, direct connection to the PLC’s local I/O modules may be impractical or unfeasible. In these cases, instrumentation shall be connected directly to the PLC via remote I/O over a standard protocol

(such as Ethernet/IP, EtherCAT, Modbus, etc.)

e. Where an Allen-Bradley PLC is used and a remote I/O network is required, remote I/O modules shall be of either Compact 5000 (5069) or Point I/O (1734) series.

f. All selections of PLC-related components, including controllers, adapters, modules, and others, requires approval by BSA.

g. All controllers shall be operated at a nominal voltage of 24 V DC.

h. Where an application utilizes an Allen-Bradley PLC, the newest available firmware shall be installed on the controller. The installed firmware must support Version 32.11 of Studio 5000 at minimum.

i. All controllers shall provide a free ethernet connection for establishing communication via the NSLS-II

Instrumentation (INST) network. The Contractor shall configure the controller according to INST network requirements prior to installation of the controller or equipment. Remote I/O networks, where deployed, must be independent from the INST network. If a controller does not provide an independent ethernet connection for this purpose, use of an industrial NAT (such as Allen-Bradley 1783-NATR) may be permitted for INST connectivity with BSA approval.

2.6 Digital IO

a. All signals which are provided for monitoring as digital inputs, less triggers (see section 2.8), shall be volt-free dry contacts and used in a “sinking” configuration. All such digital inputs shall be rated for nominal 24 V DC excitation (“ON” state) and nominal 0 V DC in the “OFF” state. (Example: a signal emitted by a cryocooler to tell the control system that the cryocooler is running)

b. All signals which are intended to be provided by digital outputs, less triggers (see section 2.8), shall be volt-differential contacts (the voltage may be referenced to the equipment which receives the output) and used in a “sourcing” configuration. All such digital outputs shall provide a differential across the contacts of nominal 24 V DC in the “OFF” state and nominal 0 V DC in the “ON” state. (Example: a signal sent to the cryocooler to prohibit cooling the load)

c. All signals which are intended to be provided by digital outputs, less triggers, but which cannot themselves provide a voltage, shall be volt-free dry contacts and used in a “sinking” configuration. All such digital outputs shall be rated for nominal 24 V DC excitation (“ON” state) and nominal 0 V DC in the “OFF” state. (Example: a solenoid used to open and close a vacuum isolation valve)

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d. All signals which are intended to be provided by digital outputs, and which provide their own voltage, shall be appropriately fused to protect against sustained short-circuit conditions, equipment damage, and overheated conductors. All digital outputs which provide a voltage shall be likewise fused.

e. The preferred connector type for all digital signals is the D-sub family, with normal density 15-pin and

9-pin configurations being ideal. Other types of connectors are permissible. All connector standards for an application shall be approved by BSA and in accordance with facility standards.

f. Where a digital signal is part of a protection system, has high consequence for failure (e.g., lost experimental time), or else is of critical importance, the polarity of the signal shall be designed to be fail-safe. For example, a provided input may be normally closed when in the desired state, such that a disconnected or broken cable is seen as an undesired state by the monitoring system.

g. Any input, device, component, equipment, etc. that requires activation by a digital output (e.g., from a

PLC, relay, or switch) shall operate at a nominal 24 V DC, with a maximum sustained current draw of

200 mA. All current draw shall be reasonably minimized as feasible for the application. Some examples for minimizing draw include utilizing a smaller solenoid, selecting LEDs with a lower brightness rating, choosing a flow controller with fewer unnecessary features.

h. Where an application requires any deviation from the specifications as described in this section, such deviations shall be identified by the Contractor and require approval by BSA prior to implementation.

2.7 Analog IO

a. All signals which are provided for monitoring as analog inputs, less temperature monitors, shall be of milliamp signal type with a range of 4 mA to 20 mA It is preferred for the measurement to scale linearly with current, i.e. for the upper range value to correspond to 20 mA and the lower range value to correspond to 4 mA. Loop-powered monitors are ideal, but not required.

b. All signals which are intended to be provided by analog outputs shall be of milliamp signal type with a range of 4 mA to 20 mA It is preferred for the measurement to scale linearly with current, i.e. for the upper range value to correspond to 20 mA and the lower range value to correspond to 4 mA. Loop-powered receivers are ideal, but not required.

c. The following signal types may be considered for analog inputs and outputs, if justified by the Contractor to be required by the application, or else if explicitly requested by BSA: “0 V DC to +10 V DC”, “-10 V

DC to +10 V DC”, “0 V DC to +5 V DC”, “0 mA to 20 mA”. Use of these signal types requires approval by BSA. If voltage signals are used, they shall be fused at the source to protect against sustained short-circuit conditions, equipment damage, and overheated conductors.

d. All signals which are provided for monitoring as analog inputs, and which are temperature monitors, shall be of either Type-K thermocouples, Pt100 385 RTDs, or transmitted after conversion to a standard analog signal type (i.e. 4 to 20 mA). Where thermocouples are used, cold-junction compensation shall be appropriately applied to the monitor.

e. The preferred connector type for all analog signals is the D-sub family, with normal density 15-pin and

9-pin configurations being ideal. Other types of connectors are permissible. All connector standards for an application shall be approved by BSA and in accordance with facility standards. For thermocouples, matching connectors (i.e. chromel/alumel conductors) may be requested by BSA.

f. Where an analog signal is part of a protection system, has high consequence for failure (e.g., lost experimental time), or else is of critical importance, the polarity of the signal shall be designed to be fail-safe. For example, a provided input may be non-zero (i.e. not 0 V or 0 mA) when in the desired state, such that a disconnected or broken cable is seen as an undesired state by the monitoring system.

g. Where an application requires any deviation from the specifications as described in this section, such deviations shall be identified by the Contractor and require approval by BSA prior to implementation.

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2.8 Triggers

a. All generated triggers (outputs) shall be TTL signal levels. That is, signals shall be 5 V DC in the steady

“ON” state and 0 V DC in the steady “OFF” state. While traditional TTL specification allows outputs in the “ON” state as low as 2.4 V, this voltage level is deemed insufficient. A stronger high level of at least

4 V is required (while loaded by a receiver). In the “OFF” state, the traditional specification of up to 0.4

V is acceptable.

b. All trigger (TTL) outputs shall be rated to supply the amperage necessary sustain a constant 5 V DC in the “ON” state. This rating shall be no less than 150 mA.

c. All trigger inputs shall accept TTL signal levels. That is, signals of 2.0 V DC and greater shall be considered the “ON” state and no more than 0.8 V DC for the “OFF” state.

d. All trigger (TTL) inputs shall be rated to maintain a constant 5 V DC in the “ON” state. This rating shall be no less than 150 mA.

e. All trigger (TTL) outputs and inputs shall be provided as BNC male connectors of RG-58 type.

Terminations for inputs shall be rated at a nominal 50-ohm input impedance and any interconnects shall be made using coaxial cable of 50-ohm characteristic impedance.

f. All trigger (TTL) transition delays (rise/fall times) shall be sufficiently fast as to avoid ringing or chattering at the receiver(s). Both propagation and transition delays shall be fast enough to ensure proper function and consistent performance of all equipment which sends or receives a trigger.

2.9 Cameras

a. The NSLS-II standard bus type for digital cameras is Gigabit Ethernet (GigE Vision).

b. The NSLS-II standard digital cameras are Prosilica and Manta. Specific camera model choice requires approval by BSA.

c. The use of other digital camera buses requires approval by BSA.

d. Analog cameras shall only be used after approval from BSA.

e. All digital cameras shall be "Power over Ethernet" (PoE) compatible. Any exception to this requires approval by BSA.