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GIANO: user manual for cryogenic instrument and controls Version

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1. Interlock emergency button check position of red emergency button of PLC TT401 Temperature sensor of cold trap TE 401 not connected This alarm disappears only when the cold trap is mounted It does not affect the PLC operations GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 14 of 15 Table 3 7 2 Non common alarms which could be recovered without special maintenance TSH Q Temperature of PLC electric board out of range HE101 Fault of power supply to heaters switch off heaters or re install fuses for special use of heaters with cold trap see Sect 2 3 MAXTIME Cold trap did not reach the low temperature setup check LN2 supply to cold trap YVA401 modify maximum time of cold trap filling TE101 Fault of TE101 need modifying FTD1 see Sect 3 6 TE102 Fault of TE102 need modifying FTD2 see Sect 3 6 DT101 2 Inconsistent values of TE101 and TE102 need modifying FTD1 2 see Sect 3 6 TE301 Fault of TE301 need modifying FTD1 see Sect 3 6 TE302 Fault of TE302 need modifying FTD2 see Sect 3 6 DT301 2 Inconsistent values of TE201 and TE302 need modifying FTD1 2 see Sect 3 6 Table 3 7 3 Alarms that indicate hardware failures requiring special maintenance P201 Fault of rotary pump P202 Fault of turbo pump YY201 Fault of gate valve on rotary pump YY202 Fault of gate valve on turbo pump Seq Vac Error in auto
2. Besides the common dangers associated to the use of cryogenic liquids e g skin burns the only risk for the instrument is that of a forced thermal cycle with consequent loss of scientific operations for about 5 6 weeks This could occur if somebody forgets to refill or replace the external LN2 reservoir In such a situation the tank will only receive compressed air instead of LN2 from the external reservoir If humidity and other impurities are present in the compressed gas they could form a frozen cup which blocks the LN2 pipelines inside the cryostat Once this cup has formed it becomes impossible to refill LN2 into the cryostat One must wait until the instrument has warmed up and the frozen cup has dissolved 2 3 Risks related to heaters The instrument also includes heaters and a cold trap which could be used to perform a fast 3 4 days warm up during special maintenance under the direct control of the manufacturers The cold trap is normally dismounted and it cannot be mounted while the instrument is cold Consequently the heaters must not be used in normal situation The risk of using the heaters without cold trap is a contamination of the spectrometer optics by the hydrocarbons produced by the out gassing of the heaters To avoid this risk we physically disconnected the fuses 4FU1 on the power supply line of the PLC 2 4 Secondary control systems of the instrument In parallel with the industrial control system GIANO
3. cryogenic instrument and controls Oct 18 2013 Page 7 of 15 Figure 3 2 1 Vacuum panel The Vacuum Data panel Fig 3 2 2 shows the following information PT 201 Absolute gas pressure at the rotary pump PT 202 Absolute gas pressure inside the chamber YY 201 Status of the gate valve between rotary and turbo pump YY 202 Status of the gate valve between the turbo pump and the vacuum chamber P 201 Status of the rotary pump P 202 Status of the turbo pump FLCEMER Flag for auto pump on in case of abnormal pressure in vacuum chamber PCEMER Threshold for abnormal pressure in vacuum chamber The last two parameters can be modified by the user They are used to setup and extra safety operation which automatically switches the pumps on whenever the instrument is cold and the pressure of the vacuum chamber goes above a given threshold A typical value for PCEMER is 5E 5 values lower than 1E 5 are not recommended WARNING when this safety operation is activated the PLC stops the automatic LN refill flag FLN2C see Sect 3 4 GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 8 of 15 PCEMER mbar FLCEMER Figure 3 2 2 Vacuum data panel The panel Manual Operation must not be used It is only intended for special maintenance operations under the direct control of the manufacturers 3 3 Pressure panel This panel is used to monitor and control the pressure of the out boiling LN2
4. for the TNG interface Parameter Requirement Actual Comment Instrument Nas A room Nas A room Compliant positioning Light pick up OIG focus via OIG focus via Compliant fibers fibers Acquisition and NIR camera in NIR camera in Compliant guiding pre slit module pre slit module SARG like SARG like guider interface guider interface Electric Power UPS 380V 6 kW 380V 6 kW Compliant 220V 1 kW 220V 1 kW Compressed air 1 line gt 6 bar 1 line gt 6 bar The PLC goes into an alarm state Dry air Dry air which blocks all operations as soon as the air pressure drops The same alarm occurs if the air filter of GIANO is full of water Gas exhaust 2 lines 2 lines 1 line for exhaust oil contaminated fumes of rotary pump 1 line for out boiling GN2 LN2 supply for 30 liters day 30 liters day The LN2 must be in a pressurized 0 5 normal operations bar tank connected to the cryostat LN2 supply for 800 liters in 3 800 liters in 3 The LN2 must be in a pressurized 0 5 cooling down days days bar tank connected to the cryostat GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 5 of 15 The spare parts of the custom spectrometer includes a window slits filters flat mirrors grating cryogenic motors temperature sensors The vacuum cryogenic part is made by off the shell components which can be purchased directly from the manufacturers 2 1 Safety of t
5. includes three custom control systems which were developed in Arcetri The first is in the small box attached in front of GIANO It is used for the detector read out The second is in the large electronics rack on the right hand side of GIANO It provides the power to the detector control system and it supervises the temperature sensors and the cryogenic motor drivers The third is in the large electronics rack on the left hand side of GIANO It supervises the mechanisms in the pre slit slit system including the calibration box This last part was first delivered in July 2013 and completed in Oct 2013 The spare parts include a complete copy of the detector control electronics see RD9 RD10 RD11 one replacement for the embedded PC and of the control board for the second control system and one U Ne calibration lamp GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 6 of 15 To simplify the powering and reset operations of the secondary control systems it is convenient to plug the large electronics racks into power sockets which are remotely controlled by the TNG control system 3 PLC and PLC control panel The PLC of GIANO is a commercial system whose hardware and software are made according to industrial standards One of its fundamental characteristics is to protect the cryo vacuum system against any foreseeable problem To this purpose whenever a power failure or a major alarm occurs the PLC locks al
6. sensor is damaged FTA2 On off flag for TE 302 can be set to off when PT100 sensor is damaged GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 13 of 15 Figure 3 6 2 Heather Data panel 3 7 Alarms panel This panel lists the status of all the alarm flags and allows one to reset those which have been activated The reset operation works only if the reason which caused the alarm has been resolved Please note that a power off of the PLC does not reset pending alarms see Sect 3 1 The tables 3 7 1 3 7 2 and 3 7 3 list and describe of the alarms Another list and description of all the PLC variables and alarms as well as their byte mapping for the MODBUS communication is available in RD11 Table 3 7 1 Common alarms which can be normally recovered PSL901 Pressure of compressed air too low or air filter to be purged the compressed air entrance is on the back right hand side TSL103 TE 103 too low normally means overflow of LN2 during re filling just need to modify WEIGHT_MAX and wait for warming up of GN2 pipeline TSL104 TE 104 too low normally means overflow of LN2 during re filling just need to modify WEIGHT_MAX and wait for warming up of GN2 pipeline C201 Cooling system of turbo pump did not start check power switch on top of yellow box on the back FSL201 Cooling fluid does not flow to turbo pump check level of glycol in yellow box on the back Em
7. GIANO user manual for cryogenic instrument and controls Version 1 4 October 19 2013 Authors Name Affiliation Ernesto Oliva INAF Arcetri Andrea Tozzi INAF Arcetri Luca Roccia Omicron Sistemi via F Parigi 32a Chivasso TO Guido Roveta Criotec impianti s r l via F Parigi 32a Chivasso TO Francesca Ghinassi INAF TNG Manuel Gonzalez INAF TNG Livia Origlia INAF Bologna GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 2 of 15 Change Record Issue Date Sections Reason affected 1 0 Sep 7 2013 All First issue early release without screen shots of PLC panel 1 1 Sep 8 2013 All Added figures with screen shots of PLC panel 1 2 Oct 17 2013 2 1 2 3 3 7 Added turbo valve to be protected dismounted heaters disconnected extended list of alarms 1 3 Oct 18 2013 3 2 3 3 3 4 Added infos on delay times after pumps off details on pressure control parameters constraints on cooling speed 1 4 Oct 19 2013 3 4 updated list of alarms Reference documents RDI Gennari et al 2006 The spectrometer optics of GIANO TNG SPIE 6269 127 RD2 Gennari et al 2006 The mechanics and cryogenics of GIANO TNG SPIE 6269 128 RD3 Mochi et al 2008 Performances of the cryogenic system
8. he cryo vacuum system The only truly dangerous occurrence is a loss of vacuum i e a gas leak sufficient to increase the pressure above 10 mbar when the cryostat is cold This would cause the formation of ice outside and inside of the whole spectrometer It could irreparably damage the optical components and or the detector Luckily this problem is virtually impossible to occur because the vacuum system is sturdy and well proofed It can maintain a good level of vacuum for many months even when subject to mechanical disturbances as it occurred when it was shipped to the TNG Such a disaster can only be produced by manually opening one the three valves which can let air into the cryostat The first is the large gate valve for the cold trap on the right hand side of GIANO This valve is marked with a warning sign and is blocked by a mechanical system which requires a special tool for opening The second valve on the left hand back side of GIANO is marked with a warning sign and blocked by two mechanical systems which require special tools for dismounting The third is a small needle valve on the side of the turbo pump in a hardly accessible position below the vacuum chamber This valve will be mechanically protected or removed by F Ghinassi 2 2 Risks related with LN2 refilling and cooling down The cooling down and refilling of LN2 is under the supervision of the PLC The operations are performed using the Level panel see Sect 3 4
9. inside the tank The main panel Fig 3 3 1 shows the absolute pressure of the tank and allows one to start stop the automatic control of the pressure Figure 3 3 1 Pressure panel The Pressure Data panel shown in Fig 3 3 2 includes extra information and allows one to modify the set point value of the pressure SET_PT101 the flag that activate the PID control PAUTO and the parameters of the PID control The value of PT101_SET must be about 10 mbar above the yearly maximum value of ambient pressure The PAUTO flag must be On The PID parameters must not be modified i e they must be PIG_G 12 0 PID_TI 1 20 PID_TD 0 00 GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 9 of 15 TE102 fer cit 1 TODAY a mbar J 85 00 S mbar Figure 3 3 2 Pressure Data panel 3 4 Level panel This panel is used to monitor the level of LN2 and to control the cooling and LN2 re filling system The level of LN2 is given by the weight of the cryostat WT 100 which is shown in the main panel Fig 3 4 1 minus the weight of the empty cryostat The latter value must be manually recorded before cooling down the instrument The tank capacity is about 70 kg overflowing of LN2 is automatically handled by the PLC alarms of TE103 and or TE104 see Sect 3 7 The main panel also displays the cooling heating rate DTHR in K hr This parameter which is updated every 60 seconds is used to monitor c
10. l LN2 tank can get empty in just a few hours An additional risk is related to the cooling speed of the detector that according to the manufacturer must be lt 6 K hr The fundamental parameters which control the cooling are MAPVLN2 and MAXDTHR The first determines the flow of LN2 into the tank Typical values for MAPVLN2 are 25 35 but are difficult to predict because the flow rate of LN2 also depends on other parameters such as the pressure and the level of the external LN2 tank The value of MAXDTHR is used to avoid an exceedingly fast cooling rate If the cooling rate DTHR becomes faster than MAXDTHR the PLC progressively closes the LN2 valve Once DTHR has dropped below MAXDTHR the PLC progressively re opens the LN2 valve A safe value of MAXDTHR is 15 K hr larger values may result in a too fast cooling rate of the detector A typical problem one could encounter is a very irregular cooling rate with long periods of low LN2 flow followed by sudden gulps and fast decreases of the temperature of the tank This condition does not pose any risk on the system as long as MAPVLN2 lt 35 MAXDTHR lt 15 and the pressure of the external LN2 tank is lt 0 5 bar However it may abnormally prolong the cooling procedure and cause an excessive consumption of LN2 This may become particularly annoying if the cooling operation is interrupted for many hours e g during the night In such a situation one typically needs gt 3 days to cool the tank belo
11. l the gate valves and stops any on going operation In such a condition safe state the cryo vacuum system is safe but cannot be refilled with LN2 The alarms set by PLC can be reset directly accessing the PLC control panel suitable only for super users or remotely via a TBD common user interface see Sect 1 which communicates with PLC via its dedicated serial MODBUS protocol In the following we describe the operations which can be performed using the PLC panel 3 1 Power on off emergency button and alarms The emergency button forces the PLC into safe state The same effect is achieved by turning the PLC off At power on the PLC is always in an alarm status equivalent to that set by the emergency button The reset to normal status is achieved by pressing the square reset key below the panel Other alarms can only be reset through the Alarm panel see Sect 3 7 Powering the PLC off does not reset the alarm status 3 2 Vacuum panel This panel includes the commands and parameters relative to the vacuum pumps The main panel Fig 3 2 1 shows the pressure inside the cryostat PT 202 and allows one to start or stop the pumps All the commands to the pumps valves and relative interlocks are directly handled by the PLC After a pumps stop or an alarm the cooling of the turbo pump remains active for 15 minutes while the start key remains non active This delay time cannot be modified GIANO user manual for
12. matic sequence of vacuum pumps PT101 Fault of pressure sensor of LN2 tank PT201 Fault of pressure sensor of rotary pump PT202 Fault of pressure sensor of cryostat FCV101 Fault of mass flow control system on GN2 line WT100 Fault of weight sensors TE103 Fault of PT100 sensor on GN2 line TE104 Fault of PT100 sensor close to mass flow control system Figure 3 7 1 Alarms panel first page GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 15 of 15 Figure 3 7 2 Alarms panel second page 3 8 Setting panel This panel can used to modify the contrast and the sensitivity of the touch screen The other options must not be used Figure 3 8 1 Setting panel
13. of GIANO are the subject of a TBD document to be prepared by a TBD staff member of the TNG in charge of the common user interface for GIANO An experimental version of such an interface developed for the laboratory in Arcetri see RD7 may be used as starting point 2 The vacuum chamber and the cryostat A detailed description of the instrument is given in RDI to RD4 For the purpose of this document we summarize that the GIANO spectrometer is mounted on a rigid aluminum bench thermally connected to a LN2 tank Following the ray path from the entrance window the spectrometer includes a flat window a cold stop a filters wheel a slit the spectrometer optics 7 mirrors 3 prisms 1 grating and a 2k HgCdTe detector array All these elements are included inside a vacuum chamber which is permanently connected to all the sub systems pipelines valves pumps sensors PLC necessary to create maintain monitor and control the vacuum and the cryogenic status of the spectrometer All the operations are performed and supervised by the PLC see RD11 The PLC is controlled through a dedicated panel see Sect 3 The fundamental requirements for the functioning of the spectrometer are summarized in the compliance matrixes reported in RD4 We replicate here table 2 1 the information relative to the interfacing to the TNG which were updated after the Jul 2012 and Jul 2013 commissioning runs Table 2 1 Characteristics performances and compliance matrix
14. of GIANO TNG SPIE 7014 125 RD4 Origlia amp Oliva 2012 Pre commissioning report version 2 dated 23 April 2012 RDS _ Baffa et al 2006 The versatile acquisition system of GIANO SPIE 6274 25 RD6 Oliva et al 2012 Performances and results of the detector acquisition system of GIANO TNG SPIE 8453 103 RD7 Baffa amp Giani 2011 Il programma di telemetria lillend l interfaccia web Arcetri Technical Report 7 2011 RD8 Biliotti 2012 Elettronica di acquisizione di GIANO descrizione di insieme Arcetri Technical Report 6 2012 RD9 Biliotti et al 2012 Elettronica di acquisizione di GIANO interfaccia digitale Arcetri Technical Report 8 2012 RD10 Biliotti 2012 Elettronica di acquisizione di GIANO parte analogica a temperatura ambiente Arcetri Technical Report 9 2012 RD11 Oliva et al 2009 Specifiche per il PLC di controllo di GIANO version 13 5 june 2009 Acronyms GIANO Name of the instrument not an acronym GN2 Gaseous Nitrogen LN2 Liquid Nitrogen NIR Near InfraRed PLC Programmable Logic Computer PT100 Platinum Thermo resistor with 100 Ohm at 0 C TBC To Be Confirmed TBD To Be Defined GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 3 of 15 Content Contee 3 I SCOPE niet EREET EEE I EERON ESE cecetensedecdessvedesGostaeccessteese 4 2 The vacuum chamber and the cryostat cccccssc
15. of the cryostat kg YY102 Status of the by pass valve on LN2 line Figure 3 4 2 Level Data panel The panel Manual Operation must not be used It is only intended for special maintenance operations under the direct control of the manufacturers 3 4 1 LN2 automatic refilling This operation is activated by setting the FLN2C flag and manually starting the filling operation The first phase which lasts TIMELN2V seconds is used to cool down the external LN2 tube After this LN2 flows into the pipeline feeding the LN2 tank inside the instrument Under normal conditions the filling continues until the weight of the cryostat WT 100 reaches a user defined maximum value WEIGHT_MAX Alternatively the filling could stop after a given time out TOPEN_MAX this normally means that the external LN2 tank is empty The filling may also GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 11 of 15 stop because the tank is over filled In such a case the PLC goes into an alarm status see Sect 3 7 When this occurs it is necessary to decrease the value of WEIGHT_MAX 3 4 2 Cooling the instrument The cooling is a non standard complex and potentially risky operation It requires the continuous presence and supervision of one or more persons with specific knowledge of the instrument The risks related to the cryogenic system are those described in Sect 2 2 and are particularly serious because the externa
16. ontrol the cooling and heating operations The upper limit for this rate absolute value is defined by MAXDTHR This parameter can be modified by the user allowed range 0 99 Figure 3 4 1 Level panel D00 K h MaxptHR 50 0 GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 10 of 15 The Level Data panel Fig 3 4 2 includes the following parameters which can be modified by the user MAPVLN2 Max aperture of LN2 valve when tank is warm see Sect 3 4 2 MAXVLN2 Max aperture of LN2 valve when tank is cold typical value 100 TDCRIT Temperature below which the tank is cold typical values 80 85 K FLN2C Automatic refill flag must be set to 1 to activate auto refill WEIGHT_MIN Min weight of cryostat auto refill activates if WT 100 lt WEIGHT_MIN WEIGHT_MAX Max weight of cryostat auto refill stops if WT 100 gt WEIGHT_MAX DT_MAX Max time seconds from last LN2 refill typical value 85000 TOPEN_MAX Max time seconds of LN2 refill typical value 3000 TIMELN2V Time seconds for cooling external LN2 tube typical values 100 200 TUBLN2M 1 parameter controlling by pass valve on LN2 line must always be 0 TUBLDIS 2 parameter controlling by pass valve on LN2 line must always be 1 The Level Data panel also includes the following information LV101 Actual aperture of the LN2 valve in i e from 0 to 100 TE103 Temperature of output GN2 pipeline WT100 Actual weight
17. ssssssscccsssccsssccecscsssssccsscesesessssscsssseeseeses 4 2 1 Safety of the cryo vacuum system i 5 2 2 Risks related with LN2 refilling and cooling down 5 2 3 Risks related to heaters Hera lalla lc 5 2 4 Secondary control systems of the instrument 5 3 PLC and PLC control panel ccccssssssssecccsssscsssscececsssscsssscceescesssscscceeesessssscssssoesessens 6 3 1 Power on off emergency button and alarms ii 6 3 2 VACUUM panel AR i 6 3 3 Pressure panelei a aerate OO ORA aiar 8 BA bevek panel Rosi a AA geet E i 9 3 41 ENZ aut mat reint eei AR ae ki ee natali 10 3 4 2 Cooling the instrument ii iaia allinea 11 3 5 Colditrap panel men errereen aoo ere aea aee EESTE aa AREE E e E e o aS 11 3 6 Heaters paneli i pa dorica lau Aiino aL Ai 11 Body Alarms panel iosa era Epto EE E nie rete 13 3 8 Setting pan liss tifi noire dat iene E T ae ariete 15 GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 4 of 15 1 Scope This document describes the operations necessary for the GIANO instrument and its relative control systems WARNING this document is intended only for the use of specialized persons with specific knowledge of the instrument In particular it includes the description of operations which may be potentially dangerous for people and for the instrument itself The common user operations necessary for the day to day use
18. w 85K temperature at which the LN2 can be safely stored inside the tank Once this condition is reached the cooling procedure becomes much easier because it only requires re filling the tank before it is gets empty again 3 5 Cold trap panel This panel is used to control the cold trap which is normally not mounted It is used only for special maintenance by the manufacturers see Sect 2 3 3 6 Heaters panel This panel is used to control the heaters inside the vacuum chamber The heaters are physically disconnected They can only be used in combination with the cold trap see Sect 2 3 GIANO user manual for cryogenic instrument and controls Oct 18 2013 Page 12 of 15 Figure 3 6 1 Heather panel However the panel Heather Data Fig 3 6 2 contains the following parameters which could be useful for normal operations TE101 Temperature of LN2 tank as read by first PT100 sensor on tank TE102 Temperature of LN2 tank as read by second PT100 sensor on tank TDAV Average temperature of LN2 tank average between TE 101 and TE 102 FIDI On off flag for TE 101 can be set to off when PT100 sensor is damaged FTD2 On off flag for TE 102 can be set to off when PT100 sensor is damaged TE301 Ambient temperature as read by first PT100 sensor TE302 Ambient temperature as read by second PT100 sensor TAAV Average ambient temperature average between TE 301 and TE 302 FTAI On off flag for TE 301 can be set to off when PT100

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