Attachment (B4) NSLSII-CRL-STD-001_v8.pdf

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NSLS-II Design Standard Doc. No.: NSLSII-CRL-STD-001 Version 8

Beamline Systems Instrumentation Interfacing Standard

Beamline Systems Instrumentation Interfacing Standard

August 16, 2023

NSLSII-CRL-STD-001

Version 8

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National Synchrotron Light Source II ii 16AUG2023

Beamline Systems Instrumentation Interfacing Standard August 16, 2023

Document Reviewed and Approved By:

Prepared By O. Biletskyi DSSI Electrical Engineer Reviewed By1 A. Broadbent Partner Beamline Portfolio Manager Reviewed By1 A. Derbenev DSSI Group Leader Reviewed By1 S. Wilkins DSSI Program Manager Reviewed By1 R. Skelaney DSSI Engineering & Equipment Pool Reviewed By1 M. Zhanay DSSI Engineering & Equipment Pool Approved By2 J. Keister Engineering & Equipment Pool Group Leader Approved By2 J. Sinsheimer Instrument & Controls Group Leader Approved By2 R. Todd Vacuum Group Leader 1I have reviewed this Design Standard as a system expert and my signature indicates that I agree with these standards and they are applicable as written.

2By approving this Design Standard I acknowledge the requirements set forth herein and approve its implementation.

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National Synchrotron Light Source II iii 16AUG2023

Version History

Version Description List of Reviewers Date

1 First version ready for release. See cover 13MAY2011 2 Updates include: Servo phase wiring definition and limit switch pin labelling clarification. (Section 3.3.5.1);

Motion direction standard clarification. (Section 3.1) See cover 04APR2012

3 Change pinouts for encoder connector at equipment end (Section 3.5.1): Update Souriau backshell details (Section 3.3.3) See cover 27JUN2012

4 Add connector details and pinout for potentiometer feedback device (Section 3.6.1); Add connector details and pinout for actuated devices (Section 0); Clarify connector type for vacuum valves (Section 2.3) See cover 22AUG2012

Clarified piezo vacuum interlock (Section 3.8); Clarify thermocouple types and interfaces (Section 0);

Clarify actuated device interface for diagnostics and shutters (Sections 4.6, 4.8 and 4.9); Removed interface details for PPS shutters (Section 4.8); Added Section 6.2.1 defining location and orientation of equipment patch panel; Moved motor controller encoder pinout definition (Section 3.5.2); Clarified requirements for Hall Effect sensors (Sections 3.2.2, 0, 3.5.2); Added section on DC servo motors (Section 3.2.2); Clarified operation of NSLS-II motion controller limit switch inputs (Section 3.3); Defined mains power connectors on interface panel/box(Sections 6.2.1, 6.8) Changed pinout for overtravel switches (Section 4.3); Changed pinout for PT100 temperature sensor (Section 4.4.1); Added connector type and pinout for general purpose digital IO (Section 5.2) Added section on Hall effect sensor pinout (Section 3.5.1.6); Fixed contact type for motor cable limit switches (Section 3.3.3.7); Changed minimum conductor size for limit switch signals (Sections 3.3.3.1, 3.3.3.6, 3.3.5.1); Change wording for multiple RTD connector (Section 4.5.1); Add images of DSub connectors (Sections 3.5.1.6, 4.4, 4.5.1, 5.2); Update pinouts for terminal servers (Section 6.7) Updated approval signature block (Remove individual beamline; group leaders, add ABBIX and NEXT beamlines group leaders, remove controls engineers, change ESH signatory); Added Controls RSI to list of referenced documents.

See cover 09APR2013

Added motor brake interface definition. (Section 3.11) Added BiSS absolute encoder interface definition (Section 3.5.1.3) Add captions to all tables.

Remove reference to non-existent Appendix C (Section 3.3) Simplified flow switch definition (Section 4.2) Added definition of interface to Beamline PLC allowing direct remote IO connection (Sections 4.1, 5.1) Add gender for thermocouple connector (Section 4.5.2) Added controller pinout for absolute encoders (Table 12, Section 3.5.2) Removed statement of Pt100 as 'standard' temperature sensor (Section 4.5.1) Removed statement of thermocouple as 'acceptable' temperature sensor (Section 4.5.2) Added motor cable twisted pair requirement (Section 3.3.3.1) Fix references to tables (Section 3.3.3.6, 3.3.5.1) Added cable labelling section (Section 6.6) Consistent pinout for RTD sensors (Section 4.5.1)

See cover 28NOV2016

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National Synchrotron Light Source II iv 16AUG2023

Reformatted to meet the requirements of NSLSII-DPT-PDN-001, NSLS-II Process Description:

Management of NSLS-II Documents. Scope expanded (1.1). Updated references and added vacuum chamber wiring exception (1.4.2). Elaborated on EPS system (2.3). Temperature and component clarifications made in section 3. References updated in 6.1. Added section on documenting cable (6.2).

Updated review signatures.

See cover 20FEB2020

Minor formatting/editorial corrections throughout document. Acronyms: Removed FAT, FDR; Added RGA.

Section 1.5: Updated document numbers + references throughout document. Section 3.3.3.2: Updated link to Souriau Motor Connector. Section 3.5.1.2: Removed hyperlink to drawing. Section 3.5.1.3: Removed hyperlink to drawing. Table 10, 11, 13: Added (Female). Table 26: Updated Item, Description, and Example columns. Section 6.6.1/6.6.2: Added Cable Labeling image. Section 6.6.3: Added section defining the Items from Table 26, Added Cable Labeling Examples section. Section 7: Added references to engineering drawings. Added Appendix C and D.

See cover 16AUG2023

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National Synchrotron Light Source II v 16AUG2023

Table of Contents Acronyms ................................................................................................................................. viii

1 Introduction

1.1 Scope Definition

1.2 Scope Exclusions

1.3 Statutory Requirements of the Supplier

1.4 Other General Requirements

1.4.1 Protection of Electronic Equipment from Radiation

1.4.2 Cable Construction and Materials

1.5 Applicable Documents

2 Vacuum

2.1 Vacuum Instrumentation

2.1.1 Gauge Controller

2.1.2 Thermal Conductivity/Convection Pirani Gauges

2.1.3 Cold Cathode Gauge

2.1.4 Partial Pressure Gauge (Residual Gas Analyzer [RGA])

2.2 Vacuum Interlocks

2.3 Vacuum Valves

2.4 Sputter-Ion Pumps (SIPs) and Controllers

2.5 Oil-free Roughing Pumps

2.6 Turbo Molecular Pumps

2.7 Bakeout

3 Motion Control and Device Instrumentation

3.1 Motion Direction

3.2 Stepper Motors and DC Servos

3.2.1 Stepper Motors

3.2.2 DC Servo Motors

3.3 General Motor Connections

3.3.1 Limit Switches

3.3.2 Homing Switches

3.3.3 Low-power Stepper Motors

3.3.4 High-Power Motors

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National Synchrotron Light Source II vi 16AUG2023

3.3.5 DC Servo Motors

3.3.6 AC Motors

3.3.7 Other Motor Types

3.4 Motion Control Local E-Stop

3.4.1 Motion Controller Abort/Watchdog Connector

3.5 Encoders

3.5.1 Component Encoder Pinout

3.5.2 Motor Controller Encoder Pinout

3.5.3 In-vacuum Encoders

3.6 LVDTs and Potentiometer-Type Position Sensing Devices

3.6.1 Potentiometers

3.7 Strain Gauges

3.8 Piezo Actuators

3.9 Digital Length Gauge Devices

3.10 High Precision Motion Actuators

3.11 Brakes

4 Beamline Protection and Interlocks

4.1 Interface to Beamline PLC

4.2 Flow Protection Switches

4.3 Flow monitoring

4.4 Overtravel Limits

4.5 Temperature Monitoring

4.5.1 Resistive Thermal Devices (RTDs)

4.5.2 Thermocouples

4.5.3 Other Temperature Sensors

4.6 Beam Diagnostics

4.7 Pressure Interlocking

4.8 Shutters

4.9 Position-indicating Switches

5 General Purpose IO

5.1 Interface to Beamline PLC

5.2 Digital IO

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National Synchrotron Light Source II vii 16AUG2023

5.3 Analog IO

5.4 Actuated Devices

6 General NSLS-II Standards and Service Provisions

6.1 Electrical Wiring Diagrams

6.2 Cabling and Labyrinths

6.2.1 Equipment Patch Panel

6.3 Interconnections

6.4 Trigger Connections

6.5 Cable Routes and Tray

6.6 Cable Labeling

6.6.1 Intra-rack Cable Labels

6.6.2 Inter-rack Cable Labels

6.6.3 Rack to Equipment Cable Labels

6.6.4 Equipment Cabling

6.7 Connections to EPICS

6.8 Electrical Wiring Requirements

6.9 Shielding

7 References

Appendix A: UT0 Connectors – Quick Reference

Appendix B: Subminiature D-Type connectors – Quick Reference

Appendix C: DSSI Internal Technical Tables for Termination and Installation Purposes

Appendix D: Cable Assembly Drawings

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National Synchrotron Light Source II viii 16AUG2023

Acronyms AC Alternating Current

ADC Analog to Digital Converter

AMU Atomic Mass Unit

AWG American Wire Gauge

BSA Brookhaven Science Associates

DC Direct Current

EMC Electromagnetic Compatibility

EPICS Experimental Physics and Industrial Control System

EPS Equipment Protection System

E-Stop Emergency Stop

HV High Voltage

IEEE Institute of Electrical and Electronics Engineers

IOC Input/Output Controller

LSZH Low Smoke, Zero Halogen

LVDT Linear Variable Displacement Transducer mV Millivolt

NEC National Electric Code

NRTL Nationally Recognized Testing Laboratory

NSLS-II National Synchrotron Light Source II

PLC Programmable Logic Controller

PPS Personnel Protection System

PSD Position Sensing Device

RGA Residual Gas Analyzer

RTD Resistive Thermal Device

SHV Safe High Voltage

SIP Sputter-Ion Pump

SOW Statement of Work

TC Tray Cable

TTL Transistor-Transistor Logic

UHV Ultra High Vacuum

UL Underwriters Laboratories

V Volts

VAC Volts Alternating Current

VDC Volts Direct Current

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1 Introduction

1.1 Scope Definition

This document defines the low voltage electrical connectivity and interfacing for motion control, vacuum control, and diagnostic equipment within a photon beamline and endstation at NSLS-II.

This document provides a set of guidelines which will ensure that all the electrical components in a beamline can be integrated into the control system, allowing all aspects to be controlled and monitored from one terminal. It is also the intention to promote commonality of components wherever possible.

A few non-electrical criteria are included in the scope of this document.

Appendices A and B present a summarized list of standard connectors (Souriau UT0 and Type D connectors) adopted by NSLS-II for reference.

1.2 Scope Exclusions

Data acquisition in the endstations is excluded from the scope of this document. This document does not cover the main electrical power supply and interfaces.

1.3 Statutory Requirements of the Supplier

This document is not exhaustive and does not remove the obligation on suppliers to comply with any and all applicable statutory instruments. It is the supplier's responsibility to ensure conformance of each technical detail at the commencement of any supply contract.

1.4 Other General Requirements

1.4.1 Protection of Electronic Equipment from Radiation

Radiation shielding shall be provided where required for devices exposed to radiation or, if electrically acceptable, the solid-state device should be located outside the hutch.

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1.4.2 Cable Construction and Materials

All cables supplied for installation at NSLS-II shall be Low Smoke, Zero Halogen (LSZH), except wiring inside a vacuum chamber.

All cables to be installed in a cable tray shall be rated for Cable Tray use. The cable shall have the TC (Tray Cable) and NRTL markings. Where a cable is not marked for Tray Cable use, then cable shall meet the IEEE 1202 Vertical-Wire Flame Test. Further information on cable management between devices and controllers can be found in the process description NSLSII-CRL-PDN-001, Beamline Cable Management.

1.5 Applicable Documents

Table 1: Referenced Documents

Document Number Document Title

NSLSII-CRL-STD-002 Beamline Coordinate Systems Standards

NSLSII-CRL-RSI-001 Experimental Facilities Requirements, Specifications and Interfaces for the Controls and Data Acquisition System

NSLSII-LT-ELECT-DESIGN-0001 Electrical Design Room Instructions and Standards.

2 Vacuum Many parts of the beamline must be maintained under vacuum. All vessels, devices etc., will require adequate vacuum pumping, gauging, control, and isolation. Overall control of the valves will be provided by a standard Equipment Protection System (EPS), which will also provide interfacing with the EPICS control system. It is envisaged that the various pumps will be run continuously except during essential maintenance.

2.1 Vacuum Instrumentation

There will be several different vacuum instruments employed on the NSLS-II machine and beamlines. They are described in the following paragraphs.

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2.1.1 Gauge Controller

The gauge controller shall power and control several gauges’ heads and provide the analog, relay, or TTL signals for interlocking. The NSLS-II standard vacuum gauge controller is the MKS 937B.

The preferred communication interface for gauge controllers will be serial, conforming to RS- 232/422/485. All other wiring (e.g., to the gauge heads) will be using the manufacturer’s standard cable schematics and connectors.

2.1.2 Thermal Conductivity/Convection Pirani Gauges

The thermal conductivity/convection Pirani gauges have a range of Atmosphere to 1 x 10-3 mbar and connect to the vacuum vessel via a DN 40 CF or DN 16 CF flange. They feed signals to a gauge controller directly. The connection is to be made in accordance with the manufacturer’s instructions.

2.1.3 Cold Cathode Gauge

The cold cathode gauge has a pressure measuring range of 1 x 10-2 mbar to 1 x 10-11 mbar and connects to the vacuum vessel via a DN 40 CF flange. The connecting cable will be LSZH, tray rated, and UL listed unless otherwise approved by BSA in writing. The connection is to be made in accordance with the manufacturer’s instructions.

2.1.4 Partial Pressure Gauge (Residual Gas Analyzer [RGA])

The system includes an analyzer probe, controller, and interface unit. Its analyzer head shall be mounted on a DN 40 CF flange. The device will have a mass range of 200 AMU. The connecting cable will be LSZH, tray rated, and UL listed unless otherwise approved by BSA in writing. The connection is to be made in accordance with the manufacturer’s instructions.

2.2 Vacuum Interlocks

Equipment supplied to NSLS-II requiring interlocks (e.g., to prevent the operation of piezo elements at vacuum levels where electrical arcing could occur) shall have the interlock functionality documented at the appropriate design review and in the operating manual.

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2.3 Vacuum Valves

The vacuum isolating valves shall be UHV compatible and all metal. They are available in flange sizes from DN 40 up to DN 200. The vacuum valves are pneumatic, although DN 40 and DN 63 manual valves may also be used.

The pneumatic valve actuator shall be double acting and include open/close limit switches (plus redundant spares when requested). Nominally, a 24 V DC solenoid, when energized, will activate the pneumatics for an OPEN valve condition. The exceptions to this nominal configuration in vacuum valve control (dual latching solenoids or solenoid activates CLOSED valve condition) must be first explicitly explained and approved by BNL. A reason for this exception can be a manipulator arm travels through the OPEN gate valve region. Having the valve prematurely closing on the manipulator due to a power loss can damage multiple devices.

The limit switches will be utilized as feedback for both the valve controller and EPS (The EPS system nominally acts as the valve controller.) The connection is to be made in accordance with manufacturer’s instructions. For VAT valves, the manufacturer's standard connector type and pinout shall be used. For other valve manufacturers, BSA approval of the connector type and pinout is required.

2.4 Sputter-Ion Pumps (SIPs) and Controllers

The ion pump requirements will be met using a range of pumps including 100 l/s, 150 l/s, 300 l/s, and 500 l/s. The pump element assemblies shall be of a diode configuration. The controller to EPICS interface is realized using RS232/422/485. The SIP operates typically at 5 kVDC.

The ion pumps will connect to the vacuum vessel via DN 100 CF or DN 160 CF flanges. They will require connection to their controller using customized cable. The connecting cable will be LSZH, tray rated, and UL listed unless otherwise approved by BSA in writing. The connectivity is as follows:

The HV connection is made using a 10 kV coaxial cable. It connects to the controller via a special Kings SHV coaxial connector. There is also an integral safety connection which only allows the HV supply to operate when both ends are properly connected.

The SIP controller shall be located in the beamline electronics rack, outside of any hutch.

The bakeout heaters shall be supplied and mounted to the pump body, operate at 110 VAC, and capable of maintaining the temperature >200 °C. Temperatures of 250 °C are to be avoided unless the magnet is removed.

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2.5 Oil-free Roughing Pumps

There will be a requirement for oil-free roughing pumps either on carts or permanently installed.

Any requirements for roughing pumps require concurrence from the electrical and vacuum groups.

Details of the standard roughing pumps will be provided upon request.

2.6 Turbo Molecular Pumps

There may be a requirement for turbo pumps either on carts or permanently installed. Any electrical requirement for a turbo pump must be established with the electrical and vacuum groups.

Details of the NSLS-II standard turbo molecular pumps will be provided upon request.

2.7 Bakeout

Bakeout procedures and equipment must be approved by the NSLS-II Vacuum Group. Any bakeout jackets or tapes must be 110 VAC and incorporate thermocouple over-temperature measurement to prevent excessive heat damaging the equipment.

3 Motion Control and Device Instrumentation Many of the devices required to complete a beamline require accurate motion control. Stepper motors are the standard, and preferred, NSLS-II solution for conventional motion axes. All motorized motions shall have limit switches and should also be fitted with encoders where appropriate. Wherever possible, the number of variations shall be kept as small as practicable to reduce the spares requirement. Piezo actuators are acceptable where there are special motion requirements (e.g., high precision/small step) for the axis that cannot be met with a conventional stepper motor.

For applications that require solutions other than stepper motors, the supplier shall agree on motor and drive card combinations with BSA.

The interface to the NSLS-II standard motion controller is defined in NSLSII-CRL-RSI-001. For motors requiring up to 5A at 50V or less, this controller can directly drive 2/4 phase stepper motors and DC servo motors. For higher or lower-power motors, the controller will provide differential step (pulse) and direction signals.

Any motion axis using an AC motor will require a variable frequency drive unit. This must be capable of interfacing with EPICS via the digital interface board or compatible communications medium.

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Where appropriate, in-vacuum devices should be kept to a minimum. Any in-vacuum devices on a component that will be baked, including motors and wiring, must also be suitable to 120° C unless documented otherwise.

3.1 Motion Direction

The definition of positive motion for the motion controller is in the “Motion Controller” subsection of the “Control System” section of NSLSII-CRL-STD-002, Beamline Coordinate System Standards.

The motor shall be wired according to the pinouts defined in 3.3.3.6 or 3.3.5.1. If this results in the opposite axis motion direction to that required, the motion direction should be inverted in the motion controller configuration.

3.2 Stepper Motors and DC Servos

3.2.1 Stepper Motors

NSLS-II has preference for 2-phase, bipolar stepper motors. The connection of any extra wires (i.e., from six- or eight-wire motors) must be made between the motor and the motor connector so the interface to the at the equipment patch panel is effectively a four-wire bipolar configuration.

All six or eight lead stepper motors shall be wired in “parallel” configuration, unless otherwise specified.

Units should be capable of direct mounting to an assembly via frame-mounted fixing holes rather than a clamp arrangement. Wherever possible, frame sizes shall be standard NEMA sizes (example: NEMA-23).

Any motor situated within a vacuum vessel shall be vacuum rated (e.g., AML or Phytron types or equivalent) and should include provision for temperature monitoring/protection. The resolution of an in-vacuum axis must be achieved in full-step mode in order to keep the holding current at the minimum possible level or to allow the motor amplifier to be disabled without losing its position.

In-vacuum motors require electrical screening of the connection leads. Since the lead assembly for an in-vacuum motor is usually individual Kapton insulated wires, the connection wiring will require an overall metal screen connected at both the motor and the vacuum feedthrough connector.

5-phase stepper motors may be used on beamline equipment where two phase stepper motors are not available or cannot meet the specifications, but details should be provided to BSA for review and approval prior to use on the Equipment. Wiring connections will be approved on a case-by-case basis.

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3.2.2 DC Servo Motors

DC servos may be brushed or brushless, with a preference for brushless motors. Where brushless servo motors are used, a suitable method for measuring the commutation angle shall be provided.

The NSLS-II motion controller has inputs for Hall Effect sensors as defined in Section 3.5.1.5.

3.3 General Motor Connections

The motor cable and connector specification is detailed below. This is split into two sections; Low-power motors are defined in Section 3.3.3, while high-power motors, such as those used on insertion devices, are defined in Section 3.3.4.

All limit and home switches on the NSLS-II standard motion controller operate with a common voltage supply to the switch contacts, with the return going to the limit or home switch contact on the motor connector.

3.3.1 Limit Switches

Limit switches are used to define the limit of the travel. They are used to provide protection against mechanical damage. Limit switches can also be used as a reference/home switch. The resolution and hysteresis of the limit switch should be appropriate to its function (i.e., limit only or limit and reference combined).

All motorized axes shall be fitted with a minimum of one limit switch at each end of travel.

Limit switches shall be mechanical switches, with normally closed, dry, volt-free contacts rated at 24 VDC. Any variation from this specification must be approved in writing by BSA.

The use of alternative solutions such as normally open mechanical switches, open-collector, or TTL limit signals is strongly discouraged.

Limit switches shall be interfaced with the controller in such a way as to be consistent with the definitions of “positive motion”, referenced in 3.1 (i.e., the limit switch associated with maximum travel in the positive direction shall be interfaced with the motor controller’s positive limit input for that axis). The same logic shall apply to other switches associated with a given physical axis (e.g., “kill switches”).

3.3.2 Homing Switches

Switches that are to be used as homing or reference indicators shall have a low switching hysteresis and a highly repeatable switching position. The precision required will be determined by the requirements of the specific motion axis.

Homing switches shall have dry, volt-free contacts rated at 24 VDC.

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3.3.3 Low-power Stepper Motors

This section covers low-power motors, typically operating below 50 V and 5 A.

3.3.3.1 Motor Cable

The following specifies suitable motor cable for stepper motor systems. Limit and home switches and motor power may be combined in the same main cable core. They shall be twisted pair separately shielded to prevent interference between the motor drive signals and the home/limit signals.

Motor cores: 3 x 2 x 0.75 mm2 (min) with overall shield (alt AWG 18)

Limit/home cores: 3 x 2 x 0.20 mm2 (min) (alt AWG 24)

3.3.3.2 Motor Connectors

Connectors are all-metal UTO (Trim Trio) series by Souriau, or equivalent. Shell size is 14, with an insert arrangement of 12 contacts (Part Number - UT001412PH):

https://usa.souriau.com/en-en/uto-series-uto-series-uto-series-uto-series-uto-series-uto-series-metal-ip6869k-connector-495

The connection strategy is to avoid live exposed pins. All motors shall be terminated close to the motor at termination panels or directly on the motor using flying leads.

3.3.3.3 Motor Controller (or Motor Controller Termination Panel)

Table 2: Motor Connection at Controller Panel

Item Comment Part Number

Motor controller (or motor controller termination panel)

Wall mounting receptacle, socket contacts

UT0 01412 SH

Strain relief Metal shell with strain relief UT0 14JCSL https://usa.souriau.com/en-en/uto-series-uto-series-uto-series-uto-series-uto-series-uto-series-metal-ip6869k-connector-495 https://usa.souriau.com/en-en/uto-series-uto-series-uto-series-uto-series-uto-series-uto-series-metal-ip6869k-connector-495

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3.3.3.4 Motor Connection

In the case of the connector being mounted to a mounting panel, the following connector shall be utilized:

Table 3: Motor Connection at Equipment End

Item Comment Part Number

Panel-mounted motor connector

Wall mounting receptacle, pin contacts UT0 01412 PH

Strain relief Metal cable clamp with strain relief UT0 14AC

In the case of the connector being mounted to motor flying leads, the following connector shall be utilized, with appropriate strain relief:

Table 4: Motor Connection on Flying Lead at Equipment End

Item Comment Part number

Cable mounted motor connector

Cable mounting receptacle, pin contacts

UT0 11412 PH

Strain relief Metal shell with strain relief UT0 14JCSL

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3.3.3.5 Cable Connector Convention

The connection strategy avoids exposed live pins, hence the connectors on each end of the cable are not the same. This table shows the cable connectors, with strain relief at both ends.

Table 5: Motor Connection for Motor Cable

Item Comment Part Number

Motor cable connector (motor controller end)

Cable mounting receptacle, Pin contacts

UT0 61412 PH

Motor cable connector (motor end)

Cable mounting receptacle, Socket contacts

UT0 61412 SH

Strain relief (both ends) Metal shell with strain relief UT0 14JCSL

Strain relief (for limited space areas)

Metal cable clamp with strain relief UT0 14AC

3.3.3.6 Motor Cable Pin Assignments

Figure 1: Connector viewed from plug mounting face, contact side

12 Way

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Table 6 shows pin assignments for 2-phase stepper motor and limit cables.

Table 6: Stepper Motor Connector Pinout

Pin Pin No.

Min Conductor

Conductor Color General Description

A 1 0.75 mm2 Not used Motor GND

B 2 0.75 mm2 Orange of Orange/White

Motor A+

C 3 0.75 mm2 White of Orange/White

Motor A-

D 4 0.75 mm2 Blue of Blue/Black Motor B+

E 5 0.75 mm2 Black of Blue/Black Motor B-

F 6 0.75 mm2 Cable Shield (at male end only)

Cable Shield GND

G 7 0.20 mm2 Green of Green/Yellow

Positive Limit Switch

H 8 0.20 mm2 Yellow of Green/Yellow

Negative Limit Switch

J 9 0.20 mm2 Brown of Brown/White

Home Switch

K 10 0.20 mm2 Pink of Pink/Grey 5 V limit supply

L 11 0.20 mm2 White of Brown/White

24 V limit supply

M 12 0.20 mm2 Grey of Pink/Grey 0 V

Note: Limit and home switches operate with a shared voltage supply (Pin K or L).

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Figure 2: Example limit switch connection schematic using common 24 VDC supply

3.3.3.7 Motor Cable Contact Specification

Machined contacts shall be used in all connectors. The contact size shall be Souriau #16.

The contact wire connection size shall be appropriate for the wire size. Part numbers for the contacts currently in use are in the following table. Crimp connectors shall be used wherever possible.

Table 7: Motor Cable Contacts

Cable size (AWG/mm2) Pin contact Socket contact

18/0.75 (motor cores) RM16M23K RC16M23K

24/0.20 (limit switch cores) RM24M9K RC24M9K

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3.3.4 High-Power Motors

High-power motors are defined as those requiring greater than 5 A of continuous current at more than 50 V. In this case, the proposed NSLS-II standard motion controller’s integrated drives are insufficient to power such motors, so external amplifiers must be supplied. The controller-amplifier control interface for external stepper and servo drives (so-called stepper replacement drives) shall be differential step and direction signals, such that the amplifier is compatible with the NSLS-II standard motion controller interface.

3.3.5 DC Servo Motors

DC servo motors are treated the same as stepper motors as described in Section 3.3.3, except for the connector pin assignment. Hall Effect sensors shall be routed to the motor controller in a separate cable.

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3.3.5.1 Motor Cable Pin Assignments

Table 8 shows pin assignments for DC Servo motor and limit cables.

Table 8: Servo Motor Connector Pinout

Pin Pin No.

Min Conductor

Conductor color General description

A 1 0.75 mm2 Not used Motor GND

B 2 0.75 mm2 Orange of Orange/White

U Phase

C 3 0.75 mm2 White of Orange/White W Phase

D 4 0.75 mm2 Blue of Blue/Black V Phase

E 5 0.75 mm2 Black of Blue/Black NC

F 6 0.75 mm2 Cable Shield (at male end only)

Cable Shield GND

G 7 0.20 mm2 Green of Green/Yellow Positive Limit Switch

H 8 0.20 mm2 Yellow of Green/Yellow

Negative Limit Switch

J 9 0.20 mm2 Brown of Brown/White Home Switch

K 10 0.20 mm2 Pink of Pink/Grey 5 VDC limit supply

L 11 0.20 mm2 White of Brown/White 24 VDC limit supply

M 12 0.20 mm2 Grey of Pink/Grey 0 V

Note: Limit and home switches operate with a shared voltage supply (Pin K or L).

3.3.6 AC Motors

The use of AC motors is relatively unusual on beamlines and agreement must be received from the responsible technical person prior to their inclusion in any equipment. In any event they shall be wired in accordance with the manufacturer’s written instructions.

3.3.7 Other Motor Types

Any motor type not explicitly covered in this document shall only be used with BSA approval.

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3.4 Motion Control Local E-Stop

Any motion that could potentially cause injury to personnel, or that could cause damage in the event of a collision, must have a local E-Stop connected to allow emergency isolation in the event of a failure. The design of this E-Stop system shall meet all applicable standards and regulations.

3.4.1 Motion Controller Abort/Watchdog Connector

The standard NSLS-II motion controller has an interface to allow an external abort signal to be sent to the motion controller. When it receives this abort signal, the motion controller will perform a controlled deceleration.

The motion controller provides an output indicating the watchdog status. The pinout for this connector is in Table 9.

Table 9: Abort/Watchdog Connector Pinout

Pin General description

A 0 V

B Controller enable/abort

C Watchdog NC

D Watchdog Common

E Watchdog NO

F Signal to reset external relay

G Signal to reset external relay

H 24 V

To enable the motion controller operation, Pin H must be connected to Pin B. Disconnecting 24 V from Pin B causes the motion controller to execute the abort process.

The watchdog signals are relay contacts and can be used as a signal the motion controller status to an external system.

Pins F and G are an output from the motion controller that can be used to reset a safety relay or similar device if that is required. It is not expected that these pins will be used at NSLS-II.

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3.5 Encoders

Encoder resolution shall be appropriate to the motion axis for which the encoder is providing feedback. The preferred solution is an optical encoder. X-ray shielding of these encoders shall be considered at the equipment design stage.

Absolute encoders shall be used wherever there is a requirement for position recovery without initialization after a power failure.

Motion axes that do not require an absolute encoder may be fitted with an incremental encoder.

These axes shall have a reference mark in the form of an encoder precision reference signal, precision datum switch or precision limit switch.

3.5.1 Component Encoder Pinout

The field connection to the encoder should be made via a 15-way D-type bulkhead connector or directly to encoder electronics (e.g., interpolator). The connector at the equipment panel shall have pin contacts.

3.5.1.1 Incremental Quadrature Encoder Pinout at Equipment

The pinout to be provided at the equipment end for incremental quadrature encoders is defined in.

Table 10. If the encoder manufacturers pinout does not match this pinout, an adapter cable shall be used to provide the defined pinout at the equipment patch panel.

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Table 10: Incremental Quadrature Encoder Pinout (Female)

Pin Incremental encoder feedback

1 NC

2 0 V

3 NC

4 Ch C-

5 Ch B-

6 Ch A-

7 Encoder power (5 V)

8 Encoder power (5 V)

9 0 V

10 NC

11 NC

12 Ch C+

13 Ch B+

14 Ch A+

15 NC

3.5.1.2 Incremental Quadrature Encoder Pinout at Controller-Side Patch Panel

Where a controller-side patch panel is used, the incremental encoder pinout is defined in Table 11.

The conversion from Delta Tau pinout to Renishaw pinout occurs between the controller and this patch panel. The connection from this patch panel to the equipment-side encoder connections uses a straight-through cable.

Drawing LT-EL-XF-BL-WHS-0001-07 defines the incremental encoder cable assembly details.

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Table 11: Incremental Encoder Controller-Side Patch Panel Pinout (Female)

Pin Incremental encoder feedback

1 NC

2 0 V

3 NC

4 Ch C-

5 Ch B-

6 Ch A-

7 Encoder power (5 V)

8 Encoder power (5 V)

9 0 V

10 NC

11 NC

12 Ch C+

13 Ch B+

14 Ch A+

15 NC

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3.5.1.3 Absolute Encoder Pinout (BiSS-C Protocol)

The pinout to be provided at the equipment end for absolute BiSS-C encoders is defined in Table

12. The equipment panel connector shall be DB9 (male). If the encoder manufacturers’ pinout does not match this pinout, an adapter cable shall be used to provide the defined pinout at the equipment patch panel. Neither encoder inner shield nor outer shield are connected to encoder cable shield. Instead, encoder cable shield is connected only on the controller side through DB15 backshell.

Drawing LT-EL-XF-BL-WHS-0001-12 defines the absolute encoder cable assembly details.

Table 12: Absolute Encoder Pinout

Pin BiSS serial comms

1 Inner shield

2 MA+

3 MA-

4 5 V

5 5 V

6 SLO+

7 SLO-

8 0 V

9 0 V

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3.5.1.4 Resolver Pinout

The pinout to be provided at the equipment end for resolvers is defined in Table 13. If the encoder manufacturers pinout does not match this pinout, an adapter cable shall be used to provide the defined pinout at the equipment patch panel.

Table 13: Resolver Pinout (Female)

Pin Incremental encoder feedback

1 Excitation +

2 NC

3 NC

4 NC

5 Cos -

6 Sin -

7 NC

8 NC

9 Excitation -

10 NC

11 NC

12 NC

13 Cos +

14 Sin +

15 NC

3.5.1.5 Hall Effect Sensor Pinout

The Hall Effect sensors used in brushless servo motors or linear motors shall be terminated in a separate DSub9 (male) connector according to the pinout in Table 14.

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Table 14: Hall Effect Sensor Pinout

Pin Hall Effect Sensors

1 5 VDC

2 NC

3 NC

4 Hall sensor U

5 Hall sensor W

6 0 V

7 NC

8 NC

9 Hall sensor V

3.5.1.6 Other Encoder Pinouts

Pinouts for other encoder types shall be approved by BSA.

3.5.2 Motor Controller Encoder Pinout

The connection in the control rack will be made via a 15-way high-density D-type panel-mounted socket, EMC-shielded connector. The pinout on the NSLS-II standard motion controller is defined in Table 15.

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Table 15: Motion Controller Encoder Pinout

Pin Incremental encoder feedback Absolute encoder feedback

1 Ch A+ Not used

2 Ch A- Not used

3 Ch B+ Not used

4 Ch B- Not used

5 Ch C+ (index +) Not used

6 Ch C- (index -) Not used

7 Encoder power (5 V) Encoder power (5 V)

8 Encoder power (0 V) Encoder power (0 V)

9 Commutation Input (Hall Effect Sensor) U/Stepper Direction +

Data - (SLO-)

10 Commutation Input (Hall Effect Sensor) V/Stepper Direction -

Clock + (MA+)

11 Commutation Input (Hall Effect Sensor) W/Stepper Pulse +

Clock (MA-)

12 Commutation Input (Hall Effect Sensor) T/Stepper Pulse -

Data + (SLO+)

13 Resolver Excitation + Not used

14 Encoder Power (5 V) Encoder power (5 V)

15 Resolver Excitation - / Encode power (0 V) Encoder power (0 V)

3.5.3 In-vacuum Encoders

Encoders to be used in-vacuum must be bakeable and rated at the required vacuum level.

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3.6 LVDTs and Potentiometer-Type Position Sensing Devices

LVDTs and potentiometer-type position sensing devices (PSDs) may be required in specific applications. They may be supplied with a matched controller. A suitable interface with EPICS would be Ethernet (preferred), RS-232/422, digital, or analog. Analog inputs can be translated directly by an ADC.

3.6.1 Potentiometers

Where a direct potentiometer signal is used, a Souriau UT00128PH connector shall be provided on the interface panel. This connector may be used for up to two potentiometer signals. Pinout is defined in Table 16.

Table 16: Potentiometer Pinout

Pin General description

A Potentiometer 1 Voltage Supply

B Potentiometer 1 Output (Signal)

C Potentiometer 1 Voltage Return

D Potentiometer 2 Voltage Supply

E Potentiometer 2 Output (Signal)

F Potentiometer 2 Voltage Return

G Potentiometer 1 Shield

H Potentiometer 2 Shield

3.7 Strain Gauges

Strain gauges may be used for measuring small but highly precise movements. They are 4-wire devices that require a voltage source connection for excitation and then provide a sense output.

This will be supplied with a matched strain gauge amplifier. Suitable interface to EPICS will be Ethernet, RS232/422, or analog via a 16-bit analog input module.

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3.8 Piezo Actuators

Piezo devices can be used where precise nanometer positioning is required and there are very low torque requirements. They are typically 2-wire devices that require voltage input over several hundred volts, depending on the movement required. They are not screened, but the connections could be screened before being terminated at the controller. Typical interfacing will be either Ethernet, RS232, or analog to a dedicated piece of control equipment installed close to the Piezo actuators themselves. A step-and-direction interface to the piezo device is also acceptable. The supplier and BSA must agree on the type of controller to be used.

High-voltage piezos may require interlocking with the vacuum to inhibit movement when only under partial vacuum. Where this interlock is required, the piezo actuator should expect a dry contact signal with a closed contact indicating that piezo operation is permitted and an open contact indicating that piezo operation is prohibited.

Feedback for piezos can be from an inbuilt capacitive feedback system, a strain gauge, a digital length gauge device, an interferometer or other suitable measurement device.

3.9 Digital Length Gauge Devices

Gauge systems are used for precise length measurement. They also serve as position encoders.

Solutions come in various measuring ranges, (from 12 to 101 mm) and are available in accuracies of ±1 µm, ±0.5 µm, and ±0.2 µm. These devices can interface through RS-232/422/485, TTL outputs, or analog signals.

3.10 High Precision Motion Actuators

Specialized actuators (e.g., Picomotors) shall be supplied with a matched drive or controller. The matched controller shall provide an Ethernet or RS-232/422/485 interface.

Where the actuator is supplied with a drive only, the required interfaces are defined in the External Motor Drives section in NSLSII-CRL-RSI-001.

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3.11 Brakes

Motor brakes shall be interfaced using a clearly labelled (male) DSub9 connector on the appropriate interface panel, with pinout as defined in Table 17.

Table 17: Motor Brake

Pin Motor brake

1 Brake 1 supply

2 Reserved for brake 1 feedback

3 Brake 2 supply

4 Reserved for brake 2 feedback

5 Not used

6 Brake 1 return

7 Reserved for brake 1 feedback

8 Brake 2 return

9 Reserved for brake 2 feedback

4 Beamline Protection and Interlocks The various cooling systems associated with the beamline are designed to keep the beamline components at a suitable operating temperature by removing heat absorbed from the photon beam.

In the event of a system failing to do this, the beam must be stopped from entering the affected area. This will be achieved by shutting an upstream beam shutter in the beamline or front end.

The wiring of sensors and actuators for the Personnel Protection System (PPS) is a specialist activity and outside the scope of this document.

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4.1 Interface to Beamline PLC

Where a component has a number of instrumentation sensors that interface to the Beamline PLC, a remote IO box will be used. It is preferable to connect the instrumentation directly to the PLC remote IO modules as this minimizes the number of connections.

Where a vendor is providing a complete component, BSA may provide the required PLC remote IO modules for integration into the component. Component instrumentation shall be terminated directly to these remote IO modules. Where this is done, the interface definitions (connectors and pinouts) in subsequent sections do not need to be followed.

4.2 Flow Protection Switches

Flow protection will be provided wherever required. This will be achieved using flow switches.

They provide positive confirmation of flow in the form of normally closed volt-free contacts.

If a large number of flow switches are required, it is acceptable to group them into a larger connector and run them in a larger multicore, terminated in a 25-way D-type EMC shielded connector.

Flow switches must be placed downstream of the component being cooled.

4.3 Flow monitoring

If flow monitoring is required, the…