 Thu Jun 18 22:33:57 2020, Jon, Omnistructure, VAC, Vac hardware purchase list
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Replacement Hardware Purchase List
I've created a purchase
list of hardware needed to restore the aging vacuum system. This wasn't planned as part of the BHD upgrade, but I've added it to
the BHD procurement list since hardware replacements have become necessary. |
 Fri Jun 19 07:40:49 2020, Jon, Update, VAC, Questions/comments on vacuum
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I think we should discuss interlock possibilities at a 40m meeting. I'm reluctant to make the system more complicated, but perhaps we can
find ways to reduce the reliance on the turbo pump readbacks. I agree they've proven to be the least reliable.
While we may be able to improve the tolerance to certain kinds of hardware malfunctions (and if so, we should), I don't see interlocks triggering |
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Fri Jun 19 09:57:35 2020, gautam, Update, VAC, Questions/comments on vacuum
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For this particular email service, ideally the email should be sent out as soon as the interlock is tripped, so this would require a line of code to
be added to the main interlock code. Which I guess would require a restart of the interlock service. So let me know when you guys plan to do the dry-pump
tip seal replacement operation (when I presume valves will be closed anyways) so that we can do this in a minimally invasive way. |
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Fri Jun 19 14:03:50 2020, Jordan, Update, VAC, Forepump Tip Seal Replacement
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Tip Seals were replaced on the forepumps for TP2 and TP3, and both are ready to be installed back onto the forelines.
TP2 Forepump Ultimate Pressure: 180 mtorr
TP3 Forepump Ultimate Pressure: 120 mtorr |
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Mon Jun 22 10:43:25 2020, Jon, Configuration, VAC, Vac maintenance at 11 am
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The vac system is going down at 11 am today for planned maintenance:
Re-install the repaired TP2 and TP3 dry pumps [ELOG 15417]
Incorporate
an auto-mailer and flag channel into the controls code for signaling tripped interlocks [ELOG 15413]
We |
Mon Jun 22 20:06:06 2020, Jon, Configuration, VAC, Vac maintenance complete 
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This work is finally complete. The dry pump replacement was finished quickly but the controls updates required some substantial debugging.
For one, the mailer code I had been given to install would not run against Python 3.4 on c1vac, the version run by the vac controls since about
a year ago. There were some missing dependencies that proved difficult to install (related to Debian Jessie becoming unsupported). I ultimately solved |
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Tue Jun 23 17:54:56 2020, rana, Configuration, VAC, Vac maintenance complete
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I propose we go for all CAPS for all channel names. The lower case names is just a holdover from Steve/Alan from the 90's. All other systems are
all CAPS.
It avoids us having to force them all to UPPER in the scripts and channel lists. |
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Wed Jul 1 18:03:04 2020, Jon, Configuration, VAC, UPS replacements
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I looked into how the new UPS devices suggested by Chub would communicate with the vac interlocks. There are several possible ways, listed in
order of preference:
Python interlock service directly queries the UPS via a USB link using the (unofficial) tripplite |
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Thu Jul 9 18:00:35 2020, Jon, Configuration, VAC, UPS replacements
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Chub has placed the order for two new UPS units (115V for TP2/3 and a 220V version for TP1).
Tripp Lite SMX1000RT2U: https://www.grainger.com/product/TRIPP-LITE-UPS-System-36HW20
Tripp
Lite Smart1000LCD: https://www.grainger.com/product/TRIPP-LITE-Smart-UPS-1AYA6
They |
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Thu Jul 23 15:58:24 2020, Jon, Summary, VAC, Vacuum controls refurbishment plan
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This year we've struggled with vacuum controls unreliability (e.g., spurious interlock triggers) caused by decaying hardware. Here are details
of the vacuum refurbishment plan I described on the 40m call this week.
☑ Refurbish TP2 and TP3 dry pumps. Completed [ELOG |
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Fri Jul 24 15:40:59 2020, Jordan, Update, VAC, Installation of two new UPS units
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I installed the Tripp Lite SMX1000RT2U and Tripp Lite Smart1000LCD at the
bottom of the 1x8 electronics rack. These are plugged in to power, and are ready for testing. All other cables (serial, usb, etc.) have been left on the
table next to the 1x8 rack. |
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Mon Jul 27 15:48:36 2020, Jon, Summary, VAC, Vacuum parts ordered
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To carry out the next steps of the vac refurbishment plan [ELOG 15499], I've ordered
parts necessary for interfacing the UPS units and the analog TP2/3 controller outputs with c1vac. The purchase list is appended to the main
BHD list and is located here. Some parts |
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Tue Jul 28 12:22:40 2020, Jon, Update, VAC, Vac interlock test today 1:30 pm
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This afternoon Jordan is going to carry out a test of the V4 and V5 hardware interlocks. To inform the interlock improvement plan [15499],
we need to characterize exactly how these work (they pre-date the 2018 upgrade). I have provided him a sequence of steps for each test and will also
be backing him up on Zoom. |
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Tue Jul 28 14:11:14 2020, Jon, Update, VAC, Vac interlock test today 1:30 pm
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This test has been completed. The IFO configuration has been reverted to nominal.
For future reference: yes, both the V4 and V5 hardware interlocks were found to still be connected and work.
A TTL signal from the analog output port of each pump controller (TP2 and TP3) is connected to an auxiliary relay inside the main valve relay |
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Fri Aug 14 10:10:56 2020, Jon, Configuration, VAC, Vacuum repairs today
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The vac system is going down now for planned repairs [ELOG 15499]. It will likely take
most of the day. Will advise when it's back up. |
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Sat Aug 15 02:02:13 2020, Jon, Configuration, VAC, Vacuum repairs today
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Vacuum work is completed. The TP2 and TP3 interlocks have been overhauled as proposed in ELOG
15499 and seem to be performing reliably. We're now back in the nominal system state, with TP2 again backing for TP1 and TP3 pumping
the annuli. I'll post the full implementation details in the morning. |
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Sat Aug 15 15:12:22 2020, Jon, Configuration, VAC, Overhaul of small turbo pump interlocks
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Summary
Yesterday I completed the switchover of small turbo pump interlocks as proposed in ELOG
15499. This overhaul altogether eliminates the dependency on RS232 readbacks, which had become unreliable (glitchy) in both controllers.
In their place, the V4(5) valve-close interlocks are now predicated on an analog controller output whose voltage goes high when the rotation |
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Mon Aug 24 08:13:56 2020, Jon, Update, VAC, UPS installation
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I'm in the lab this morning to interface the two new UPS units with the digital controls system. Will be out by lunchtime. The disruptions to the
vac system should be very brief this time. |
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Mon Aug 24 11:25:07 2020, Jon, Update, VAC, UPS installation
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I'm leaving the lab shortly. We're not ready to switch over the vac equipment to the new UPS units yet.
The 120V UPS is now running and interfaced to c1vac via a USB cable. The unofficial tripplite
python package is able to detect and connect to the unit, but then read queries fail with "OS Error: No data received." The firmware has |
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Wed Aug 26 15:48:31 2020, gautam, Update, VAC, Control screen left open on vacuum workstation
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I found that the control MEDM screen was left open on the c1vac workstation. This should be closed every time you leave the workstation, to avoid
accidental button pressing and such.
The network outage meant that the EPICS data from the pressure gauges wasn't recorded until I reset everything ~noon. So there isn't |
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Fri Sep 4 15:26:55 2020, Jon, Update, VAC, Vac system UPS installation
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| The vac controls are going down now to pull and test software changes. Will advise when the work is completed. |
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Fri Sep 4 21:12:51 2020, Jon, Update, VAC, Vac system UPS installation
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The vac work is completed. All of the vacuum equipment is now running on the new 120V UPS, except for TP1. The 230V TP1 is still running off wall power,
as it always has. After talking with Tripp Lite support today, I believe there is a problem with the 230V UPS. I will post a more detailed note in the
morning. |
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Sat Sep 5 12:01:10 2020, Jon, Update, VAC, Vac system UPS installation
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Summary
Yesterday's UPS switchover was mostly a success. The new Tripp
Lite 120V UPS is fully installed and is communicating with the slow controls system. The interlocks are configured to trigger a
controlled shutdown upon an extended power outage (> ~30 s), and they have been tested. All of the 120V pumpspool equipment (the full c1vac/LAN/Acromag |
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Wed Sep 16 12:03:07 2020, Jon, Update, VAC, Replacing pressure gauges
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Assembled is the list of dead pressure gauges. Their locations are also circled in Attachment 1.
Gauge
Type
Location
CC1
Cold cathode
Main volume
CC3
Cold |
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Sat Sep 19 18:07:35 2020, Koji, Update, VAC, TP3 RP failure
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I came to the campus and Gautam notified that he just had received the alert from the vac watchdog.
I checked the vac status at c1vac. PTP3 went up to 10 torr-ish and this made the diff pressure for TP3 over 1torr. Then the watchdog kicked in.
To check the TP3 functionality, AUX RP was turned on and the manual valve (MV in the figure) was opened to pump the foreline of TP3. This easily |
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Sat Sep 19 19:37:16 2020, not Koji, Update, VAC, TP3 RP failure
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Disconcerting because those tip seals were just replaced [15417]. Maybe they were just defective,
but if there is a more serious problem with the pump, there is a spare Varian roughing pump (the old TP2 dry pump) sitting at the X-end.
I reset the interlock error to unfreeze the vac controls (leaving V5 closed). |
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Mon Sep 21 15:57:08 2020, Jordan, Update, VAC, TP3 Forepump Replacement and Vac reset
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I removed the forepump (Varian SH-110) for TP3 today to see why it had failed over the weekend. I tested it in the C&B lab and the ultimate pressure
was only ~40torr. I checked the tip seals and they were destroyed. The scroll housing also easily pulled off of the motor drive shaft, which is indicative
of bad bearings. The excess travel in the bearings likely led to significant increase in tip seal wear. This pump will need to be scrapped, or rebuilt. |
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Wed Sep 23 08:57:18 2020, gautam, Update, VAC, TP2 running HOT
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The interlocks tripped at ~630am local time. Jordan reported that TP2 was supposedly running at 52 C (!).
V1 was already closed, but TP2 was still running. With him standing by the rack, I remotely exectued the following sequence:
VM1 closed (isolates RGA volume).
VA6 closed (isolates annuli from being pumped).
V7 opened (TP3 now backs TP1, |
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Wed Sep 23 10:06:52 2020, Koji, Update, VAC, TP2 running HOT
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Here is the timeline. This suggests TP2 backing RP failure.
1st line: TP2 foreline pressure went up. Accordingly TP2 P, current, voltage, and temp went up. TP2 rotation went down.
2nd line: TP2 temp triggered the interlock. TP2 foreline pressure was still high (10torr) so TP2 struggled and was running at 1 torr. |
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Wed Sep 23 15:06:54 2020, Jordan, Update, VAC, TP2 Forepump Re-install
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I removed the forepump to TP2 this morning after the vacuum failure, and tested in the C&B lab. I pumped down on a small volume 10 times, with no
issue. The ultimate pressure was ~30 mtorr.
I re-installed the forepump in the afternoon, and restarted TP2, leaving V4 closed. This will run overnight to test, while TP3 backs TP1. |
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Tue Oct 6 14:35:16 2020, Jordan, Update, VAC, Spare forepumps
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| I have placed 3 new in box, IDP 7 forepumps along the x arm of the interferometer. These are to be used as spares for both the 40m and Clean and Bake. |
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Tue Nov 10 11:59:37 2020, gautam, Update, VAC, Stuck RV2
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I've uploaded some more photos here. I believe the problem is a worn out thread where the
main rotary handle attaches to the shaft that operates the valve.
This morning, I changed the valve config such that TP2 backs TP1 and that combo continues to pump on the main volume through the partially open |
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Wed Nov 18 17:51:50 2020, gautam, Update, VAC, Agilent pressure gauge controller delivered
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| It is stored along with the cables that arrived a few weeks ago, awaiting the gauges which are now expected next week sometime. |
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Mon Nov 23 16:33:10 2020, gautam, Update, VAC, More vacuum deliveries
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Five Agilent pressure gauges were delivered to the 40m. It is stored with the controller and cables in the office area. This completes the inventory
for the gauge replacement - we have all the ordered parts in hand (though. not necessarily all the adaptor flanges etc). I'll see if I can find some
cabinet space in the VEA to store these, the clutter is getting out of hand again... |
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Wed Dec 2 12:27:49 2020, Jon, Update, VAC, Replacing pressure gauges
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Now that the new Agilent full-range gauges (FRGs) have been received, I'm putting together an installation plan. Since my last planning note
in Sept. (ELOG 15577), two more gauges appear to be malfunctioning: CC2 and PAN. Those are
taken into account, as well. Below are the proposed changes for all the sensors in the system. |
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Thu Dec 3 10:33:00 2020, gautam, Update, VAC, TrippLite UPS delivered
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The latest greatest UPS has been delivered. I will move it to near the vacuum rack in its packaging for storage. It weighs >100lbs so care will have
to be taken when installing - can the rack even support this? |
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Thu Dec 3 14:53:58 2020, Jon, Update, VAC, Replacing pressure gauges
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Update to the gauge replacement plan (15692), based on Jordan's walk-through today. He
confirmed:
All of the gauges being replaced are mounted via 2.75" ConFlat flange. The new FRGs have the same footprint, so no adapters |
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Wed Dec 9 20:14:49 2020, gautam, Update, VAC, UPS failure
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Summary:
The (120V) UPS at the vacuum rack is faulty.
The drypump backing TP2 is faulty.
Current status of vacuum system:
The
old UPS is now powering the rack again. Sometime ago, I noticed the "replace battery" indicator light on this unit was on. But it is no longer |
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Thu Dec 10 11:07:24 2020, Chub, Update, VAC, UPS fault
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| Is that a fault code that you can decipher in the manual, or just a light telling you nothing but your UPS is dead? |
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Thu Dec 10 11:17:50 2020, Chub, Update, VAC, UPS fault
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I can't find anything in the manual that describes the nature of the FAULT message. In fact, it's not mentioned at all. If the unit
detects a fault at its output, I would expect a bit more information. This unit does a programmable level of input error protection, too, usually
set at 100%. Still, there is no indication in the manual whether an input issue would be described as a fault; that usually means a short or lifted |
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Thu Dec 10 13:05:52 2020, Jon, Update, VAC, UPS failure
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I've investigated the vacuum controls failure that occurred last night. Here's what I believe happened.
From looking at the system logs, it's clear that there was a sudden loss of power to the control computer (c1vac). Also, the system
was actually down for several hours. The syslog shows normal EPICS channel writes (pressure readback updates, etc., and many of them per minute) which |
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Thu Dec 10 14:29:26 2020, gautam, Update, VAC, UPS failure
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I don't buy this story - P2 only briefly burped around GPStime 1291608000 which is around 8pm local time, which is when I was recovering the system.
Today. Jordan talked to Jon Feicht - apparently there is some kind of valve in the TP2 forepump, which only opens ~15-20 seconds after turning
the pump on. So the loud sound I was hearing yesterday was just some transient phenomenon. So today morning at ~9am, we turned on TP2. Once again, PTP2 |
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Wed Jan 6 15:28:04 2021, gautam, Update, VAC, Vac rack UPS batteries replaced
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[chub, gautam]
the replacement was done this afternoon. The red "Replace Battery" indicator is no longer on. |
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Mon Apr 19 09:17:51 2021, Jordan, Update, VAC, Empty N2 Tanks
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When I came into the lab this morning, I noticed that both N2 tanks were empty. I had swapped one on Friday (4-16-21) before I left the lab. Looking
at the logs, the right tank (T2) sprung a leak shortly shortly after install. I leak checked the tank coupling after install but did not see a leak. There
could a leak further down the line, possibly at the pressure transducer. |
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Wed Apr 21 12:56:00 2021, Jordan, Update, VAC, Empty N2 Tanks
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Installed T2 today, and leaked checked the entire line. No issues found. It could have been a bad valve on the tank itself. Monitored T2 pressure for
~2 hours to see if there was any change. All seems ok.
Quote:
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Wed Apr 28 11:31:40 2021, Jon, Update, VAC, Empty N2 Tanks
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I checked out what happened on c1vac. There are actually two independent monitoring codes running:
The interlock service, which monitors the line directly connected to the valves.
A seaparate convenience mailer, running
as a cronjob, that monitors the tanks.
The interlocks did not trip because the low-pressure delivery line, downstream of the dual-tank |
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Wed Sep 1 14:16:21 2021, Jordan, Update, VAC, Empty N2 Tanks
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The right N2 tank had a bad/loose valve and did not fully open. This morning the left tank was just about empty and the right tank showed 2000+ psi on
the gauge. Once the changeover happened the copper line emptied but the valve to the N2 tank was not fully opened. I noticed the gauges were both reading
zero at ~1pm just before the meeting. I swapped the left tank, but not in time. The vacuum interlocks tripped at 1:04 pm today when the N2 pressure to |
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Wed Sep 8 18:00:01 2021, Koji, Update, VAC, cronjobs & N2 pressure alert
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In the weekly meeting, Jordan pointed out that we didn't receive the alert for the low N2 pressure.
To check the situation, I went around the machines and summarized the cronjob situation.
[40m wiki: cronjob summary] |
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Thu Oct 14 18:30:23 2021, Koji, Summary, VAC, Flange/Cable Stand Configuration
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Flange Configuration for BHD
We will need total 5 new cable stands. So Qty.6 is the number to be ordered.
Looking at the accuglass drawing, the in-vaccum cables are standard dsub 25pin cables only with two standard fixing threads. |
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Mon Oct 18 10:02:17 2021, Koji, Update, VAC, Vent Started / Completed
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[Chub, Jordan, Anchal, Koji]
- Checked the main volume is isolated.
- TP1 and TP2 were made isolated from other volumes. Stopped TP1. Closed V4 to isolate TP1 from TP2. |