Telescope Dome Specification SOAR Telescope Project August 25, 1999

Thomas A. Sebring Project Manager

Gerald N. Cecil Project Scientist

David Porter Opto-Mechanical Engineer

Victor L. Krabbendam Project Engineer

SOAR Dome Specification

INDEX Telescope Dome Specification.......................................................................................................1 SOAR Telescope Project................................................................................................................1 August 25, 1999..............................................................................................................................1 1. INTRODUCTION.......................................................................................................................5 2. DESCRIPTION AND SPECIFICATIONS.................................................................................6 3. STRUCTURAL REQUIREMENTS.........................................................................................14 4. ELECTRICAL REQUIREMENTS...........................................................................................16 5. CONTROL SYSTEM................................................................................................................18 6. THERMAL REQUIREMENTS................................................................................................24 7. SOAR FAcility..........................................................................................................................25 8. INSTALLATION .....................................................................................................................26 9. ENVIRONMENTAL CONDITIONS.......................................................................................27 10. General Status and Sensing System.........................................................................................29 11. SAFETY..................................................................................................................................29 12. COATINGS.............................................................................................................................30 13. RELIABILITY AND MAINTAINABILITY REQUIREMENTS..........................................30 14. ACCEPTANCE TESTING......................................................................................................32 15. PACKAGING AND SHIPPING.............................................................................................33 16. DOCUMENTATION..............................................................................................................33 APPENDIX A...............................................................................................................................35 1. ABBREVIATIONS...................................................................................................................36 2. WORKMANSHIP.....................................................................................................................36 3. MATERIALS.............................................................................................................................37 4. WELDING.................................................................................................................................39 5. PAINTING AND CORROSION CONTROL...........................................................................40 APPENDIX B...............................................................................................................................42 COMPONENT SPECIFICATIONS.............................................................................................42 APPENDIX C...............................................................................................................................43 DESIGN DRAWINGS.................................................................................................................43 APPENDIX D...............................................................................................................................44 REFERENCE DOCUMENTS......................................................................................................44 APPENDIX E...............................................................................................................................45 PANEL SYSTEM SPECIFICATION..........................................................................................45 1. Purpose.......................................................................................................................................46 2. Scope .........................................................................................................................................46 3. Background................................................................................................................................46 4. Dome System Description.........................................................................................................46 5. Requirements.............................................................................................................................47 6. Coatings.....................................................................................................................................50 7. Reliability And Maintainability Requirements..........................................................................50 8. PAINTING AND CORROSION CONTROL...........................................................................51 2 DSP99-013

SOAR Dome Specification APPENDIX F...............................................................................................................................53 CONTROLS SYSTEM DESIGN.................................................................................................53 Dome Control Concept Design.....................................................................................................54 1.0 DOME Rotational Drives and Position Sensors......................................................................55 Figure 3 - Dome / Shutter Drive Diagram. ..................................................................................56 2.0 Dome and shutter drive controllers.........................................................................................56 3.0 Shutter Drive CONTROL .......................................................................................................57 Figure 4 - Slave Shutter Controller Diagram. ..............................................................................57 4.0 Windscreen Coupling and Overload Switch............................................................................57 5.0 Crane Operation Unit and Interlock.........................................................................................58 Figure 5 - Slave Dome Controller Diagram. 3kVA additional power for the auxiliary I/O shall be provided.....................................................................................................................................58 6.0 Data Aquistion i/o and Vents...................................................................................................58 7.0 Manual User Interface (MUI)..................................................................................................59 APPENDIX B-COMPONENT SPECIFICATIONS APPENDIX C-DESIGN DRAWINGS APPENDIX D-REFERENCE DOCUMENTS APPENDIX E-PANEL SYSTEM SPECIFICATION 1. Purpose................................................................................E-Error: Reference source not found 2. Scope...................................................................................E-Error: Reference source not found 3. Background.........................................................................E-Error: Reference source not found 4. Dome System Description...................................................E-Error: Reference source not found 4.1. General.........................................................................E-Error: Reference source not found 4.2. Fixed Dome..................................................................E-Error: Reference source not found 4.3. Shutters.........................................................................E-Error: Reference source not found 4.4. Vents.............................................................................E-Error: Reference source not found 4.5. External Ladder Attachment........................................E-Error: Reference source not found 4.6. Internal Lighting Attachment.......................................E-Error: Reference source not found 4.7. Lighting Protection.......................................................E-Error: Reference source not found 5. Requirements.......................................................................E-Error: Reference source not found 5.1. General.........................................................................E-Error: Reference source not found 5.2. Mechanical Requirements............................................E-Error: Reference source not found 5.2.1. Panel Thickness.....................................................E-Error: Reference source not found 5.2.2. Core Thickness......................................................E-Error: Reference source not found 5.2.3. Thermal Insulation................................................E-Error: Reference source not found 5.2.4. System Weight......................................................E-Error: Reference source not found 5.2.5. Face Sheet Properties............................................E-Error: Reference source not found 5.3. Environmental Conditions............................................E-Error: Reference source not found 5.3.1. Operating Conditions............................................E-Error: Reference source not found 5.3.2. Survival Conditions...............................................E-Error: Reference source not found 5.4. Deflections...................................................................E-Error: Reference source not found 5.4.1. Dome Paneling System.........................................E-Error: Reference source not found 3 DSP99-013

SOAR Dome Specification 5.4.2. Shutters Panels......................................................E-Error: Reference source not found 5.5. Interfaces......................................................................E-Error: Reference source not found 5.5.1. Structural Steel......................................................E-Error: Reference source not found 6. Coatings...............................................................................E-Error: Reference source not found 6.1. Interior Coatings...........................................................E-Error: Reference source not found 6.2. Exterior Coatings..........................................................E-Error: Reference source not found 7. Reliability And Maintainability Requirements...................E-Error: Reference source not found 7.1. Design Life...................................................................E-Error: Reference source not found 7.2. Routine Servicing.........................................................E-Error: Reference source not found 7.3. Critical Spares..............................................................E-Error: Reference source not found 7.4. Modularity....................................................................E-Error: Reference source not found 7.5. Special Tools and Equipment.......................................E-Error: Reference source not found 7.6. Lifting points................................................................E-Error: Reference source not found 7.7. Lifting Fixtures.............................................................E-Error: Reference source not found 8. PAINTING AND CORROSION CONTROL....................E-Error: Reference source not found 8.1. Quality Assurance........................................................E-Error: Reference source not found 8.2. Safety and Health Requirements..................................E-Error: Reference source not found 8.3. Surface Preparation......................................................E-Error: Reference source not found 8.4. Painting Sequence........................................................E-Error: Reference source not found 8.5. Exceptions to Painting Requirements..........................E-Error: Reference source not found 8.6. Contamination and Cleaning........................................E-Error: Reference source not found APPENDIX F-CONTROLS SYSTEM DESIGN 1.0 DOME Rotational Drives and Position Sensors..............F-Error: Reference source not found Figure 3 - Dome / Shutter Drive Diagram.......................F-Error: Reference source not found 2.0 Dome and shutter drive controllers...................................F-Error: Reference source not found 3.0 Shutter Drive CONTROL................................................F-Error: Reference source not found Figure 4 - Slave Shutter Controller Diagram...................F-Error: Reference source not found 4.0 Windscreen Coupling and Overload Switch...................F-Error: Reference source not found 5.0 Crane Operation Unit and Interlock................................F-Error: Reference source not found Figure 4 - Slave Dome Controller Diagram....................F-Error: Reference source not found 6.0 Data Aquistion i/o and Vents..........................................F-Error: Reference source not found 7.0 Manual User Interface (MUI)..........................................F-Error: Reference source not found 7.1 Hand Paddle.....................................................................F-Error: Reference source not found 7.2 Dome MUI...FError: Reference source not found

DSP99-013

SOAR Dome Specification

1. INTRODUCTION The SOAR Telescope Project, hereinafter referred to as SOAR, is in an effort to design, construct, and install a 4.2-meter clear aperture telescope and support facility. The telescope is to be sited atop Cerro Pachn at the Cerro Tololo Inter-American Observatory (CTIO) in Chile. The Project is a joint undertaking of the country of Brazil, the University of North Carolina at Chapel Hill (UNC-CH), Michigan State University, and the National Optical Astronomy Observatories (NOAO). Project offices are sited at NOAO in Tucson, Arizona, U.S.A. 1.1. Objective This document is to guide the detailed design, fabrication, integration, test, debug, packaging, shipping, and successful installation of the SOAR Telescope facility Dome. The Dome will provide environmental protection, adequate strength to support all loading conditions, a telescope observing opening with shutters, and drive systems to have the opening follow the Telescope during observing. The Dome is an important part in allowing the Telescope to gather the finest quality images of any 4-meter class instrument. This specification provides a detailed design of the Dome as well as the performance requirements. The performance requirements provide the parameters to which the Dome must operate and survive, and represents the objectives of the design work performed to date. The detailed design is provided to sufficient detail to be the starting point for fabrication drawings and controls design. The objective is to provide fully developed designs to remove the engineering risk, allow detailed costing, and allow the contractor to start into fabrication details. The contractor is expected to fully review the provided design, complete design details, perform confirming and any other necessary analysis, and accept the desired Dome performance. Attempts have been made during the design to choose parts available in both Brazil and Chile but equivalent component substitutions are allowed with SOAR approval. Interfaces with other components of the facility are also defined in this document. The Contractor shall provide the exterior panel system to meet the overall Dome requirements and those included in the Panel System Specification provided in Appendix E. Contractors will be instructed to bid hours for interactive design with the SOAR Project personnel and its Contractors to insure facility compatibility and to assist in on-site Dome installation and commissioning. Additional objectives are that the Dome include minimum part count and obtain its functionality through fundamental elegance of design, exhibiting high efficiency usage of materials and components. To the extent possible, off-the-shelf components or subsystems previously designed, built, and tested should be used to minimize cost and to optimize the ability to maintain and procure spare parts. Design of components should be achieved using the most efficient and effective manufacturing processes to simplify all components and ensure lowest design and maintenance costs. 1.2. System Description The Dome is a lightweight spherical structure of approximately 20 meters (66ft) diameter. The 5/8 spherical Dome consists of a steel frame covered with a lightweight composite or aluminum weather tight panel system, shutter system, rotational friction drive system, overhead crane, windscreen and vents. The volume enclosed by the Dome is actively air conditioned during the 5 DSP99-013

SOAR Dome Specification day to the expected nighttime observing temperature. The panel system and steel are insulated to enhance thermal resistance and reduce cooling loads. The Dome is supported on an integral ring beam that transfers the loads to sixteen stationary trucks or bogies attached to the top of the facility silo. A labyrinth seal is used to provide a weather tight interface between the rotating Dome and the stationary facility. The Dome structure is designed to the worst case combination of the survival loads defined in this specification. Electrical power for overhead lights, crane, vents, and shutter are conveyed onto the rotating Dome by a slip ring. The shutter on the Dome is a double door, over the top design. The two sections nest together as they move over the top. The shutter doors are driven through a chain and sprocket drive on one panel and a differential drive on the second panel. Each shutter frame is covered with the same panels as is used on the rest of the Dome. The drive systems for both the Dome Azimuth motion and the Shutter operate by command from operator interfaces or the Telescope Control System. During telescope tracking operations the drives of the dome will be commanded to make approximately 2 degree moves every 5 minutes to allow the dome opening to track the telescope. The Dome is designed with bolted joints between major substructures to allow fast assembly at the SOAR site. The bogies and Dome drives shall be installed on the facility silo while a temporary roof is in place. The Dome is partially assembled next to the facility, the temporary roof is removed, and the partially assembled Dome will be lifted and emplaced on the stationary bogies. The panel system will be lifted in sections and attached to the steel structure. 1.3. Scope This specification and Appendices define the Dome steel structure, the paneling system, drives, bogies, vents, crane, structural, thermal, electrical, controls, interfaces, assembly, documentation, and performance requirements. Appendices of this specification include general workmanship requirements, detailed assembly drawings for the Dome structure and subsystems, purchased component specifications, procedure and analysis documentation for the provided design, the Panel System Specification, and the control system concept design. 2. DESCRIPTION AND SPECIFICATIONS This section provides functional descriptions and specifications for the Dome and subsystems. 2.1. Steel Structure The steel structure is a self-supporting welded and bolted steel construction that provides support to the shutter system, the panel system, and the crane. The structure is comprised of the ring beam and two arch girders. The ring beam transfers the total Dome loads to the stationary building through the rotational interface with the fixed bogies. The ring beam also provides the drive surface for the Dome rotation drive system.

DSP99-013

SOAR Dome Specification 2.1.1. Ring Beam The ring beam is a welded circular ring that has a box beam section. The panel system is bolted to the beam. The ring beam structure is designed for vertical and lateral stiffness as defined in Section 3.0. Drawing SD1, in Appendix B, shows the cross section. Vertical stiffness is required to allow smooth Dome rotation. The lateral stiffness of the ring reacts the arch girder lateral load transfer as well as the friction drive normal forces. The ring beam is bolted together at the site. The assembled beam shall be flat on the bearing surface to + 2mm globally, as specified on drawing SD6, to insure proper functioning of the Dome rotation. A circular hardened plate is welded to the bottom of the ring beam to form a track for the Dome to ride on the bogies. The inner diameter of the ring beam provides the rolling surface for the four friction drives. The ring beam also carries the encoder system and supports the electrical slip ring. 2.1.2. Arch Girders There are two arch girders. The arch girders are built up steel beam sections that provide the track for the shutters and support for the panel system and crane rails. The girders are bolted to the ring beam for on-site assembly. See Appendix B for the arch girder construction. The girders require high lateral stiffness as defined in Section 3.0, to maintain the shutter track alignment and to react wind loads from the panel system. Two crane support beams form a cord across each arch girder to provide the crane track. The crane support beams are bolted to the arch girders at site assembly. The required 5.0 meters diameter clear aperture for the telescope viewing determines girder separation. Lateral cross beams tie the arch girders together where the telescope viewing is not necessary. The viewing slit defined by the arch girders and cross members is defined by the required telescope clear aperture and optical axis travel of 0.25 to 75 from zenith 2.2. Panel System The system is a monocoque structure, completely self-supporting, requiring no internal or external support in static conditions. The prefabricated spherical panels use oriented reinforcements and a catalyzed resin system to achieve a high specific stiffness. The system generates a true spherical dome. The panel system envisioned is made up of insulated composite panels, such as fiberglass, or an insulated aluminum geodesic system that bolts together and is sealed at the site. The interface to the steel internal structure must accommodate the load transfer due to environmental loads, such as caused by differential thermal expansion and wind loading. The panel system can rely on the steel frame to react environmental loads and dead weight. All field assembly shall be accomplished with bolted joints. All panel interfaces shall be defined by the Contractor. The overall Dome must be watertight. The panel system provides the thermal barrier to maintain the air-conditioned observing area at the expected nighttime temperature. A thermal insulation value of 36 C/W (R-19) is required. Panels are required to cover the two shutter door frames. The panel system is assembled in sections on site and lifted onto the steel internal frame. A panel system specification is included in this document in Appendix E. 7 DSP99-013

SOAR Dome Specification 2.3. Shutter and Windscreen System A slit is required in the Dome for observing by the telescope. The slit is approximately 122 long, on a 9.9 meters radius, by 5 meters wide. The opening is defined by the Telescope clear aperture of 4.2 meters and elevation travel from zenith pointing to 75. A retractable shutter system travels over the top of the Dome to open and close the slit. The shutter is comprised of two nesting doors, a lower and upper door. The lower door is driven with a gear motor and sprocket drive attached to the doorframe through a fixed chain attached to each arch girder. The upper door motion is slaved to the lower door through a differential chain and sprocket drive mechanism for opening and closing. The lower door nests under the upper door when fully open. The shutter rides on a bearing track on each side of the door. One bearing rail shall provide lateral and vertical restraint for the door and the opposite side shall have lateral freedom to accommodate misalignment and relative motions. This bearing arrangement provides a semi kinematic design. The effect of differences in vertical alignment between the bearing system sides shall be considered. The shutter shall have software limits, limit switches, and energy absorbing stops at the ends of travel of each shutter door. A non-contacting labyrinth seal is used to seal the shutter doors to the arch girders. Electrical power is transferred to the shutter control assembly through a slip ring. A separate wind screen system, located in the lower quadrant of the opening is used to reduce wind effects on the Telescope. The fabric shutter attenuates the wind affect on the telescope but has relief cut outs to reduce the direct load on the windscreen. The fabric is attached to tubular cross members that provide stiffness and strength to the system. The cross members have guide rollers at each end that are constrained to follow a track attached to each arch girder. One roller is allowed to move axially in the cross member to prevent binding between tracks. In the retracted position the windscreen is rolled up on a spool at the bottom of the opening. The windscreen is pulled up and unrolled from the spool by the lower shutter through two cables that run along each arch girder. The windscreen shall be removable from the shutter through an easily accessible quick release coupling. Removal of the windscreen from the shutter shall not affect the shutter performance. The shutter and windscreen shall maintain an opening of 5 meters by 5 meters, large enough to satisfy the telescope clear aperture. 2.3.1. Shutter Door Description Each shutter door assembly is composed of a steel frame with four bearings and a panel. The lower shutter door provides a mount for the drive and control assembly. Structurally re-enforced ice and snow scrapers are provided on the shutter doors. 2.3.2. Shutter Drive System The shutter drive system incorporates the drive motor, gearbox, brake, drive sprockets, drive bearings, encoder read head, controller, and drive shaft. The shutter drive is attached to the lower doorframe. A tensioned fixed chain on each arch girder engages a drive sprocket assembly on each side of the moving door. The shutter drive pulls itself along the fixed chains. The drive sprocket assemblies are driven through a drive shaft and gear motor. The drive sprockets engage the chain on both sides of the shutter to provide smooth motion. The chain is tensioned with a 8 DSP99-013

SOAR Dome Specification spring to provide drive stiffness and following accuracy. The drive motor incorporates a fail safe brake (activated when power is removed) on the back end of the motor shaft. The inner door drives the outer door via a differential drive. On both sides of the upper end of the inner shutter is a 2:1 differential drive assembly. A spring tensioned fixed chain is attached to the top of both arc girders. The chain is routed through the inner shutter differential drive sprocket assembly. Another chain is attached to both sides of the outer shutter. The other half of the differential drive assembly picks up the chain on the outer shutter. As the inner shutter moves the outer shutter moves with it. The differential drive is rotated in the opposite direction by the chain attached to the arc girder. This drive rotation is transferred to the outer shutter through the differential drive into the chain attached to the outer shutter. The 2:1 speed reduction of the differential drive has the net effect of moving the outer shutter at half the speed of the inner shutter. The shutter control electronics are mounted to the inner shutter door near the drive motor. Communication between the Dome control system and the shutter control is via spread-spectrum radio frequency (RF) modem. An encoder read head is attached to the shutter door. Fixed bar code labels are attached to the underside of one arch girder. Power is transferred to the shutter via a slip ring as defined in Section 4.0. The differential drive works on the same principle as the main shutter drive. There is no drive motor for this drive. The motion of the inner shutter controls the outer shutter as described in the following text. A tensioned fixed chain is attached to the top of both arc girders. The spring is tensioned with a spring mechanism. On both sides of the upper end of the inner shutter is the 2:1 differential drive assembly. The chain is routed through the inner shutter differential drive sprocket assembly. Another chain is attached to both sides of the outer shutter. The other half of the differential drive assembly picks up the chain on the outer shutter. As the inner shutter moves the outer shutter moves with it. The differential drive is rotated in the opposite direction by the chain attached to the arc girder. This drive rotation is transferred to the outer shutter through the differential drive into the chain attached to the outer shutter. The 2:1 speed reduction of the differential drive has the net effect of moving the outer shutter at half the speed of the inner shutter. 2.3.2.1. Shutter Drive Requirements The following performance requirements shall be met in the design and development of the shutter drive. The design shall target these requirements with factors of safety and margin as appropriate to the particular designs. The shutter drive shall meet these requirements under the load and environmental conditions stated in other sections of this specification as well as all other loads incurred by subsystems of the shutter. Opening the Shutter in presence of nominal snow and ice shall be required. The shutter drive system is designed to provide this capability. 2.3.2.1.1. Shutter Drive Performance The shutter system shall have two speeds with associated acceleration profiles that can be adjusted via software interface. One faster speed will be associated with large shutter motions and the slower speed settings will be used for the small motions associated with the tracking of 9 DSP99-013

SOAR Dome Specification the telescope. The shutter is not required to continuously move to track the telescope but will be commanded to stop and start as required to maintain the opening within 1 of telescope position. The motion must be smooth and controlled. Range of Motion: Inner Shutter Door: Outer Shutter Door: Velocity Range: (Inner Door): Acceleration Range (Inner Door): Position Accuracy (moves over 2): Position Accuracy (moves under 2): 112.5 (-4.5 to 108 Elevation) 56.25 (50 to 106.25 Elevation) 0 to 2.5/s 0.1 to 0.25 /s2 1 0.25

2.3.3. Shutter Travel Limits The shutter door travel shall not limit a 5-meter diameter clear aperture centered on the Telescope optical axis as the axis travels the range of 0.25 to 75 from zenith. Each shutter door shall have three levels of stops to limit the travel. The first limit is a software limit that gracefully stops the shutter door at the end of travel. The second stop is a hardware limit (limit switch) that is activated if the door does not stop after reaching the software limit. This limit shall gracefully stop the door and not allow further commanded motion in the direction of travel while generating an alarm message. The final stop is an energy-absorbing hard stop that shall also remove the drive power until the system is manually reset. 2.3.3.1. Shutter Software Limits The Dome control system software shall contain provisions for recognizing pre-programmed encoder readout limits at either end of travel of the inner shutter. When a software limit is reached, the Dome control system shall gracefully stop the shutter motion within 1 second and send a status line to the TCS identifying the limit and encoder reading. A software-interlock shall be imposed to prohibiting further motion in the direction of the exceeded limit. Additional motion in this direction shall only be possible by issuing a special override command. The software shutdown shall occur in time to stop the shutter prior to activating the hardware limit. 2.3.3.2. Hardware Limits Each end of travel of the shutter door track shall have a normally closed limit switch located outside the software range. When a hardware limit is reached, the Dome control system shall gracefully stop the shutter motion within 1 second and send a status line to the TCS identifying the limit and encoder reading. The shutter door shall stop before reaching a hard stop. A hardware-interlock shall be imposed to prohibit further motion in the direction of the exceeded limit. Additional travel in the limit direction shall be prohibited. Motion shall only be allowed in DSP99-013 10

SOAR Dome Specification the opposite direction to the original motion, and only at less than or equal to one-tenth the maximum slew speed. 2.3.3.3. Hard Stops Cushioned energy absorbing hard stops shall be located at the end of travel for each shutter door. The location of the stops shall not limit the normal travel range of the doors. The hard stop shall be outside of the hardware limit stopping range described above. The hard stop shall absorb the energy from a free fall of the shutter doors into the stops without damage to the doors, structure, drives, or the stop. A software-interlock shall be imposed to prohibit further motion in either direction. Further servo motion shall not be allowed until a manual reset is activated. 2.3.4. Settling Time The maximum settling time under normal operation conditions shall be 10 seconds from maximum slew speed with maximum deceleration 0.25/s2. 2.3.5. Shutter Manual Operation A method to manually close the shutter shall be provided in the event the drive system fails. Currently, the design incorporates a shaft extension on the motor for attaching a drill motor. The manual operation shall be such that there is not risk to personnel or equipment during the operation. The Facility extension lift will be available to access the shutter manual drive. 2.3.6. Shutter Encoder The shutter encoder has a laser bar code read head attached to the inner shutter door with bar code labels attached to the under side of the arc girder. The read head is attached to a stiff bracket on the shutter. Adjustment for alignment of the read head shall be incorporated in the mounting. All shutter drive control loop closure is performed on the shutter. Stray reflections from the laser in the read head are unacceptable. The design incorporates a shield and brush seal to contain the laser energy. The brushes also remove dirt from the bar code labels. The output of the encoder is sent to the control electronics on the shutter. The encoder resolution shall be minimum of 0.1 to achieve the defined position accuracy. 2.3.7. Windscreen System The windscreen is a tight weave canvas fabric (trade name Sunbrella) treated to resist ultraviolet radiation. The fabric is attached to tubular cross members. Each cross member incorporates wheels on each end that ride in a track attached to the arch girder. One wheel on each cross member is allowed to float axially to prevent binding of the windscreen due to assembly tolerances and environmental loads. The fabric has cut outs as indicated in the attached drawings in each panel to reduce the wind loading on the screen and mechanical components. The cut outs reduced the maximum applied pressure due to wind to 383 Pa (8.0 psf). The windscreen is attached to a spool. A torsion spring attached to the spool provides constant tension to the screen during opening and closing. The windscreen shall have a removable handle for manual winding. 11 DSP99-013

SOAR Dome Specification 2.4. Dome Rotation Drive System The Dome shall have unlimited bi-direction travel. The drive system consists of four identical friction drive assemblies located 90 apart in azimuth. The diametrically opposed drive locations provide for balancing the normal forces applied to the ring beam by the drive wheel. The normal force is applied by a spring that provides a constant force through out the expected motion due to eccentricities in the ring beam diameter and lateral motion of the Dome. The Dome drive system is sized to operate with the combined maximum operating environmental conditions provided in this specification. 2.4.1. Dome Drive Assembly The drive assembly consists of an electric gear motor with drive wheel, and electric fail safe brake. The components are attached to a plate on linear slides. The slides allow the assembly to move radially in the plane of the ring beam. The assembly is spring loaded against the ring beam through the drive wheel. The spring is adjustable to tune the drive wheel normal force at assembly. The brake mechanisms attached to the drive shall prevent Dome rotation due to the wind during operating and survival conditions. The brakes also serve as an emergency stop system for the Dome in the event the Dome poses a threat to personnel or equipment. 2.4.2. Dome Encoder The Dome encoder is the combination of an absolute and a bi-directional incremental encoder. The absolute encoder consists of metallic barcode labels attached to the rotational ring beam and a laser read head attached at one drive location. Stray reflections from the laser in the read head into the observing area are unacceptable. A shield and brush seal to contain the laser energy shall be included. The brushes shall also serve to remove dirt from the bar code labels. This encoders function is to synchronize the bi-directional incremental encoder. The bi-directional incremental encoder shall be coupled to the Dome ring beam through a rubber wheel with a spring mechanism to insure continuous contact and avoid slippage. The overall resolution of the encoder shall be minimum 0.1 to maintain the 1 tracking accuracy required with the telescope. The high resolution bi-directional incremental encoder allows precise speed control as required for a high performance torque feedback control loop. 2.4.3. Dome Drive Requirements The following performance requirements shall be met in the design and development of the Dome. The design shall meet these requirements with factors of safety and margin as appropriate to the particular designs. The Dome shall meet these requirements under the load and environmental conditions stated in other sections of this specification as well as all other loads incurred by subsystems of the Dome. 2.4.3.1. Performance Requirements The Dome system shall have two speeds with associated acceleration profiles that can be adjusted via software interface. One faster speed will be associated with large Dome motions and the slower speed settings will be used for the small motions associated with the tracking of the telescope. The Dome is not required to continuously move to track the telescope but will be 12 DSP99-013

SOAR Dome Specification commanded to stop and start as required to maintain the opening within 1 of telescope position. The motion must be smooth and controlled. Rotational Travel: Velocity Range: Acceleration Range: Position Accuracy (moves over 2): Position Accuracy (moves under 2): Continuous 0 to 2.5/s 0.1 to 0.25 /s2 1 0.25

2.4.4. Settling Time The maximum settling time under normal operation conditions shall be 10 seconds from maximum slew speed with maximum deceleration of 0.25/s2. 2.5. Bogies Sixteen (16) identical fixed bogies mounted to the top of the facility silo at each column location shall be used to support the Dome. The bogies shall be sized to accommodate the combined survival environmental loading, live loads, and dead loads. Each bogie assembly has a single compliant vertical support roller that forms the rolling surface for the Dome, a lateral roller to maintain alignment of the Dome during rotation, and two vertical restraint rollers to react lifting loads on the Dome. The hardened steel track on the ring beam rides on the bogie assemblies. The 16 bogies are aligned coplanar on the facility silo at installation. The bogies shall be designed to accommodate up to 25 mm of adjustment for initial installation. The Bogie assemblies shall maintain clear sight from each axle to the Dome center of rotation and each axle shall include the space and features shown in the design for alignment fixtures. After alignment the bogies shall be grouted and bolted in place. 2.6. Dome Vent A minimum of 2.5m2 of ventilation area shall be provided at the top of the Dome but outside of the shutter door track. Standard weatherproof mushroom type hoods shall be provided to prevent the intrusion of precipitation, including rain, ice, and snow. The vents shall be mounted on the panel system. A grill mesh (flush with outer surface) shall be incorporated to prevent large insects and fowl access into the Dome interior. Four (4) Greenhech Model GRS-36 gravity vents, or equivalent, shall be used. The vents shall include Greenhech VCD-23 powered back draft louvered dampers or equivalent. Limit switches shall be installed to the dampers to sense opened and closed positions. The Dome Contractor shall provide power and control of the dampers. Control of the louvers shall be available through the Dome Computer or from manual switches located on the Dome. 2.7. Dome Crane A Dome crane shall be provided with the Dome for lifting telescope instruments and servicing of the primary mirror. A minimum lifting capacity of 10,000kg is required. The crane bridge moves on the rails attached to the arch girders. The radial travel of the crane from the center of the 13 DSP99-013

SOAR Dome Specification Dome is 5.8m along the centerline of the Dome defined by the observing slit. The crane is fixed in the center of the bridge and has no lateral motion along the bridge. Lateral positioning of the crane shall be achieved by rotating the Dome at reduced speed. The bridge shall be designed to provide maximum hook height and access to the telescope without interfering with the travel of the bridge. The full lifting capacity will only be used with the Dome stationary. The lifting capacity of the crane is reduced to 3,000kg if the Dome is to be rotated during the lifting operation. Telescope personnel are required to operate the crane from the lower level of the facility during Telescope maintenance. Therefore the crane shall include a wireless remote control unit. Electrical interlocks shall be incorporated in the crane drive in the stowed position. The crane specification is provided in Appendix B. 2.7.1. Crane Stowed Position and Interlocks The stowed position for the Dome crane is the maximum radial distance from the viewing slit and the hoist ring fully retracted. The interlocks in the Dome Control System shall provide an output signal to the Telescope Control System (TCS) as to whether the crane is stowed or not. The signal is used by the TCS to prevent motion of the Telescope Mount if the crane is not in the stowed position. 2.8. Seals Weatherproof seals shall be provided to prevent ice, snow, and water from entering the Dome through the shutter, and rotational drive. Low friction or non-contacting labyrinth seals shall be used to reduce the friction load on the drive systems. Seals must not be damaged by operation during freezing or ice-over conditions. The seals shall be as air tight as found practical to maintain the low friction load, account for variations in manufacturing and assembly tolerances, and motion tolerances. The complete Dome seal to the facility shall be provided by the Contractor. A method of adjustment of the seals at assembly shall be designed into the mountings. 3. STRUCTURAL REQUIREMENTS 3.1. Crane Loads The Dome shall support the crane loads for the following conditions. 3.1.1. Dome Stationary The Dome shall remain stationary when supporting the maximum crane load of 10,000kg. The Dome design shall account for the moving load due to crane bridge through full motion 3.1.2. Dome Moving The Dome shall support the reduced crane load of 3,000kg when rotating at 10% of maximum velocity. The crane bridge shall remain stationary during Dome rotation. 3.2. Mass Properties The mass properties of the Dome shall be consistent with the provided design. 3.2.1. Dome Weight The current total rotating Dome weight is estimated to not exceed 68,200kg. 14 DSP99-013

SOAR Dome Specification

3.3. Deflections The stiffness of the steel support system shall be defined by the following values with the panel system installed and the Dome installed on the compliant bogies. All deflections include stiffening effects due to the panel system. The mechanical properties for the panel system can be found in Appendix E. 3.3.1. Ring Beam The ring beam shall be fabricated to be circular in the horizontal plane when the dead load is applied. That is, a camber is designed into the beam such that the dead load forms the desired final shape. 3.3.1.1. Horizontal Plane Load Case: Survival snow and ice Change of radius in the horizontal plane (ovalizing of the ring): 5.1mm

3.3.1.2. Vertical Plane Load Case: Dead load and fully loaded crane at center of Dome. Bogie spring stiffness is 46,740kN/mm (265,000lb/in). Differential deflection between arch girder connection and a point located 90 away on the ring beam: 3.3.2. Arch Girder 3.3.2.1. Vertical Plane Load Case: Dead load and fully loaded crane at center of Dome. Bogie spring stiffness is 46,740kN/mm (265,000lb/in). Maximum deflection: 8.1mm 1.5mm

3.3.2.2. Lateral Plane Load Case: Dead load and fully loaded crane at center of Dome. Bogie spring stiffness is 46,740kN/mm (265,000lb/in). Maximum deflection: Load Case: Arch Girders: 3.3.3. Shutters Load Case: 6.3mm Maximum wind load 30.5mm Dead and survival load 2,394 kPa 15 DSP99-013

SOAR Dome Specification Maximum deflection: 12.7 mm

4. ELECTRICAL REQUIREMENTS 4.1. Electrical Power Power to the Dome will be provided by SOAR at each major subsystem location. Electrical design and equipment sizing shall be consistent with the requirements provided in this section, the site and environmental conditions, and unless otherwise specified, Chilean standards and practices. 4.1.1. Voltage, Frequency, Current and Ground A 350kVA step-down power transformer is used to provide the 2.4kV medium-voltage facility supply. The line frequency is 50Hz Chilean standard only. Frequency variation is expected to be less than 1Hz, as well as voltage variations less than 10%. Primary available power for heavy loads is 380/220V, 3 Wye connection, grounded neutral, limited distribution. For instruments, 120V as well as 220V, single-phase electric power will be available at the locations of different subsystems. When necessary, instruments can be connected to an auxiliary 120V uninterruptible power supply (UPS) also available, but not to be used for simple power filtering purposes. SOAR power, even UPS power, shall not be considered filtered. Where required, the Contractor shall provide a local filter/isolation transformer. Power may come from different sources (power transformer, UPS, emergency generator, isolation transformer), therefore the Contractor shall provide systems capable of tolerating random variations and uncontrolled power outages without damage to equipment. The Contractor shall specify the required current for each subsystem location. SOAR recommends the use of high efficiency and high power factor power supplies where possible. Heat dissipation shall be minimized to control the cost and size of the heat extraction system. To ensure that line voltage waveforms supplied to all the system are acceptably clean and to achieve high power distribution efficiency and low conducted noise, equipment must avoid contaminating the line by drawing high frequency or highly nonsinusoidal load currents. Appropriate specifications and certification procedures shall be adopted. Ground connection is also available at the different locations. Ground specifications and/or power requirements different from previously stated must be made explicit by the Contractor in their bid proposals. 4.1.2. Power Protection All electronic/electrical equipment must have over-current protections (thermal breakers, fuses, lightning arrestors, surge protection, etc.). Fuses must be easily accessible for replacement. All electronic/electrical equipment must have a main line circuit breaker or power switch, and a controlled light indicator for power status. All electrical/electronic installation must comply with National Electrical Code where applicable. WARNING: All electrical and electronic equipment in the telescope facility must have safety grounds!

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SOAR Dome Specification 4.1.3. Electromagnetic Compatibility (EMC) The Dome and its components shall minimize electromagnetic interference with scientific instruments and other telescope systems. Emissions and immunity to EMI must be considered in every part of the Dome. Electronic equipment used in the observing area must be EMI certified and comply with FCC regulation Part 15, Class B limit for emissions. For equipment used in the control or computer room, Class A limit is acceptable. All electronic equipment shall be certified IEC1000-4-2 or better for electrostatic discharge (ESD) immunity and, IEC1000-4-3 and IEC1000-4-6, or better, for RFI immunity. Immunity to power-line disturbances (IEC1000-4-9, IEC1000-4-13), electrical fast transient (IEC1000-4-4), and surges (IEC1000-4-5). 4.1.4. Lightning Protection Lightning protection shall be provided by the Contractor as an integral part of the panel system. The installation and design of the system shall meet the Lightning Protection Institute (LPI) Code 175 and National Fire Protection Association (NFPA) 780. Installation shall be made by or under the supervision of an LPI certified master installer. Complete installation to receive system certification including submittal of forms LPI 175-A and 175-B. Contractor shall provide an adequate conductive path from the main body of the Dome to the ring beam, which serves as the bearing journal for the Dome rotator. In addition, the ring beam shall contain a conductive surface suitable for contact by a system of brushes. The conductive surface shall exist opposite the lateral support roller. The lightning protection system shall be defined during the Contractors Detailed Design and approved by SOAR. 4.2. Electrical Interface Requirements 4.2.1. Connectors The Contractor shall define and provide electrical connectors, cabling, and conduit consistent with high reliability operation and EMC constraints. Connectors shall be capable of being rapidly disconnected for service of all assemblies of the Dome. Connectors shall be keyed so that incorrect connection is not possible. Proper strain relief shall be provided to ensure reliability and to minimize effect of cabling loads on the Dome performance. Only high quality rough service connectors may be used. 4.2.2. Cables Power and signal cables shall be shielded for low and high frequency interference. Whenever possible, power and signal wires must be routed separately. The cabling design must avoid ground loops. Cables designated for power must also meet the specifications for voltage and amperage capacities as per the U.S.A. National Electric Code. Cabling routed on the Dome shall be installed in conduit, flexible or rigid, and securely attached to the Dome. 4.2.3. Cable Lengths The Contractor shall provide all cables and connections between the Dome and other elements of the SOAR telescope and facility. Distances to specific rooms in the facility are defined in Section 7 of this specification. Additional distances for cables that need to travel through the facility may be determined through building layout drawings. 17 DSP99-013

SOAR Dome Specification 4.2.4. Slip Rings Power and emergency control signals to the Dome and Shutter will be passed through shielded type slip rings. The Dome slip ring will rotate with the dome, while the trolleys will be stationary. In particular, the Dome Contractor shall also incorporate mounting for the slip ring trolleys to the fixed facility. For the Shutter, the slip ring will be stationary, while the trolley will move with the Shutter. In all cases adequate short circuit protection shall be provided. There shall be no power interruptions due to poor contact between slip rings and trolleys in order to guarantee the continuous operation of all control equipment installed on the Dome and Shutter. The maximum power required by the Dome across the slip ring shall be no greater than 50 kVA. 4.3. Electronic Enclosure Requirements The Contractor shall supply enclosures for Contractor supplied electronics. Enclosures shall be a model with metal side covers, front or top, full-length doors, and leveling feet or equivalent. All electronics shall be on slide out drawers or mounted on an easily removable way. All cable connections shall be accessible from the doors of the enclosure. The enclosure shall use wiring harnesses with enough service loop to open the drawers for maintenance. Low heat dissipation is required for these enclosures. However, SOAR will be responsible for environment conditioning and heat removal of electronics located outside of the observing area. The Contractor shall make every effort to locate electronics outside the observing area. 4.4. Dome Control Electronics in the Observing Area Distributed electronic modules necessary for Dome operation and sensing shall be provided by the Contractor. Modules shall be mounted in such a way as to be easily accessible and removed for service or replacement. Modules that produce appreciable radiated or conducted heat shall be Contractor insulated. If active cooling is required, the Contractor shall provide appropriate liquid-to-air heat exchangers. SOAR will provide the glycol/water supply. 4.5. Electronic Equipment Mounting The Contractor shall design the final mounting for electronics located in the Dome. These designs shall be for such equipment as the variable frequency drives, Dome and shutter controllers, limit switches, sensors, etc. Additional equipment may be determined during the Detailed Design of the Dome. Mounting for the slip ring and trolleys shall be design by the Contractor. 5. CONTROL SYSTEM The Dome equipment shall include a complete control system capable of proper operation of all Dome functions. This system must function in the SOAR environment described in this specification and shall support control from the Telescope Control System (TCS) and Dome supplied interfaces. 5.1. General Scope The control system includes all hardware, software and interconnects necessary to operate the Dome Systems. The system shall be capable of interfacing with the SOAR TCS for remote operation and shall include a cabled hand paddle and terminal for autonomous control of the Dome System. The control system shall support the safety features described in the specification 18 DSP99-013

SOAR Dome Specification for both personnel and hardware protection. A detailed description of the control system concept design can be found in Appendix F. 5.2. Operational States The Dome shall be capable of the following states of operation. The interaction of these states is shown in Figure 5.1. Upon application of system power and successful arrival at the Power-On Self Test State, the Dome system shall be available to the operational modes defined in Section 5.3. 5.2.1. Quiescent/Power-Off (QPO) State The Dome shall be capable of maintaining a power-off state which preserves all programming, settings, variables, and other data, both default values and user defined parameters, required for all other modes and states. During this state any or all power sources to the Dome systems may be off including any high voltage feeds and UPS sources. Items operating off battery back-up will have a service life of at least one year. Storage or inactivity in a power-off mode shall not damage components or equipment. The quiescent/power-off state shall be compatible with the transition to the Power-On Self Test State. 5.2.2. Power-On Self Test (POST) State The Dome shall attain the POST Status upon application of power to the system. The Contractor shall define the process for applying power to the Dome System. Power up shall not require the telescope operators to leave the control room. SOAR will provide necessary power outlets in close proximity to the Dome subsystems. Upon power-up, the Dome shall perform selfdiagnostic checks of all computer systems and other electronics with internal self-diagnostic capabilities. The result shall be a status message of Dome system readiness, including location and type of errors identified. Provided no errors are identified, the Dome shall be defined to be in the Base Ready State. If critical errors are encountered that compromise the integrity of the control system the system shall stay inoperative in the Error State. Recovery from this condition shall be through use of a back-up initialization and diagnostic start-up procedure. The Dome shall be capable of initiating the POST state upon command from the TCS or local computer within the control room by re-booting computers rather than cycling power to them. The system shall allow power to be shut off while in the POST without loss of data or recovery by the established standard power-up sequence. 5.2.3. Base Ready (BR) State Upon successfully completing the POST due to power-on or system re-boot, the Dome system shall enter a Base Ready State. In this state the sub-systems are powered where appropriate but all drive motors remain inactive with control loops not operating. In this state the Dome system is ready for one of three control modes to take charge. Control of the Dome shall be available to the hand paddle, the TCS, or the Dome Terminal within the SOAR control room. If the TCS or Hand Paddle takes control of the system, the Dome shall automatically enter the System Health Check State. If the Dome Terminal establishes control then the system shall enter the Maintenance and Diagnostic (MD) Mode but shall not change states until commanded to do so. In this state under MD control all the system parameters and features are available for verification and manipulation.

19

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SOAR Dome Specification 5.2.4. System Health Check (SHC) State Upon command of the SHC the Dome shall initiate a series of self-tests and comprehensive diagnostics which shall, to the extent possible, test all subsystems to verify their operation within nominal specifications. Diagnostics requiring subsystem operations beyond a stand-by mode shall be available to include in the automatic nature of this state or shall be offered as user elected options. This shall include an option to do jogs for motion diagnostics and for encoder set-up. A procedure shall be available to move the Dome to a fiducial mark and initialize the Dome encoder to the zero position. All faults identified shall be reported to the TCS, clearly identifying the nature and location. All faults shall be categorized as Terminal or Degradation Faults. Terminal faults shall be identified to the unit in control and the system shall stay in the Error State. Degradation Faults, those compatible with graceful degradation of the Dome performance, shall be identified and the system shall enter the Operational Ready State as it shall without any detected faults. The Dome shall be capable of entering the SHC state from any other state. Tests and diagnostics performed in the SHC State shall not include basic level computer diagnostics that are checked during the POST state given the successful attainment of the Base Ready State. 5.2.5. Operational Ready (OPR) State The Dome shall be capable of entering the Operational Ready State upon successful completion of the SHC State. The SHC is always the route to reaching the OPR State from any lower level state. In the OPR State the system is responsive to the controlling unit, (hand paddle, TCS, Dome Terminal) with full I/O support of encoder and sensor data. The system shall respond to and act on all operational capabilities other than actual motion control. 5.2.6. Set Position (SP) State The Dome system shall enter a Set Position State (SP) when commanded from the TCS or the Dome Terminal. In this state the Dome is in closed loop condition, moving to the commanded position at the presently selected rate. Upon completion of the commanded moves, the system indicates completion and returns to the previous state from where it was commanded. This state is available to the TCS through the remote Operation Mode or the Dome Terminal through the Maintenance and Diagnostic Mode. 5.2.7. Error State The Dome enters the Error State upon detection of an anomalous condition in its internal functioning. In this state the Dome shall be inactive. The Dome leaves this state either by a reboot operation or through interaction with the Maintenance and Diagnostics (MD) mode. 5.2.8. Abort State The Abort State is entered when an abort command is issued to stop the Dome motion. After the Dome has reached a complete stop, it returns to the previous state from where the motion command was originated.

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SOAR Dome Specification

ERROR

ot bo Re

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Er

ror

Error condition

con

dit

E rr or nd co o iti n

ion

QPO

Power ON

POST

OK

Move command OK
om lC ua an
om m

BR

TCS Hand Paddle

SHC HandPaddle

an d

ABORT

MD

Figure 5.1 Dome Control State Diagram

5.3. Operational Modes The Dome control system includes three types of user interface. They are control from a hand paddle located at the observing level, a Dome terminal located in the control room, and the TCS also located in the control room. The use of each device constitutes a different mode of operation allowing for different avenues through the system. After the Base Ready State is achieved, one of the following modes of operation is chosen to continue use of the system. Changing of modes of operation shall be possible from either the Readiness State or the Operational Ready State. 5.3.1. Remote Operation Mode (TCS Control) The Dome system shall have a remote operation mode where the system is interactive with the Telescope Control System. TCS operators shall be provided with data and control of critical parameters and functions consistent with the hardware state. The system shall respond and act on all operational capabilities and support all states and sensor information requests. 5.3.2. Maintenance and Diagnostic (MD) Mode (Dome Terminal) The Dome system shall have a Maintenance and Diagnostic mode that is used from the Dome Terminal. This mode shall be password protected to maintain authorized access. The purpose of DSP99-013 21

Di ag n

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cs

MANUAL

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of

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OPR

End of move

SP

m Do

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m er et l ina

SOAR Dome Specification this mode is to allow root access to the Dome control system parameters and the ability to perform low level diagnostics for troubleshooting, maintenance, or system optimization. This mode shall have access to simulation modules necessary to perform diagnostics on all aspects of the system. MD shall be remotely accessible. An example of such a simulation is one for the TCS to invoke the Set Position State. In this mode the system can enter any hardware state. 5.3.3. Hand Paddle (Manual) Mode The Dome system shall include a hand paddle that can be used in the observing area. In this mode of operation a limited set of control features is available. As a minimum the Dome can be rotated and the shutter open and closed. More definition of the hand paddle functions is provided in Appendix F. 5.4. Platforms and Operating Systems The Main Dome Controller system shall be based on personal computers (PC) in a PCI or CompactPCI chassis. The Control System shall utilize commercially available off-the-shelf motion controllers and/or industrial process controllers. All hardware shall be consistent with the 3 modes of operation identified in section 1.4 and the operational states defined in Section 1.3. The PC connected to the SOAR TCS network shall run Windows NT or Linux. These operating systems provide the multitasking and multithreading capabilities to implement the control strategies described in this document. The use of National Instruments LabVIEW/BridgeVIEW as the software architecture and PCI/CompactPCI as the hardware architecture are requirements in this specification. 5.5. Remote Communication Requirements The Dome system shall communicate to the SOAR Telescope Control System via fast Ethernet connections. This line will handle all communication to support the interface between the TCS and Dome for all applicable modes and States of operation. The TCS will exchange information with the other parts of the SOAR system by the use of commands. A command consists of identification, a name and an optional parameter list. The name specifies the action or operation to be performed, using the optionally supplied parameters. The commands are handled by a communications library, which allows clients to establish connections to command servers, to issue commands to command servers, and to monitor the responses to commands. This communications library will be provided by SOAR, and the library implementation will be based on a socket interface library under TCP/IP. The Contractor shall implement the connection between its own internal functionality and the command protocol. If, for example, a private database model is considered, the commands supported by the subsystem would deposit or return values in the database. This would happen instantly so that an immediate reply would occur. The utilization of this command protocol also permits monitoring the state of all subsystem components. The act of monitoring the system shall in no way decrease or affect system performance. 5.6. Software The Dome system shall include software to operate the Dome in every aspect defined in this specification. The software shall include all necessary communication, motion control interface, diagnostic, and any other software necessary for the proper and safe operation of the Dome. All software shall be supplied to SOAR in listing, source, and object code form. The software shall 22 DSP99-013

SOAR Dome Specification be written in modular fashion. The use of specialized operating system facilities should be avoided, and if that is the case, they shall be properly documented. The design shall permit modifications and evolution of the code without disrupting the entire system. The implementation shall be based on National Instruments LabVIEW/BridgeVIEW software packages. It is mandatory that the Dome software links to the SOAR provided communications library. 5.6.1. Software Architecture The software shall support all the necessary data flow to achieve all the System States defined in Section 1.3 and for operation of the system in any of the three modes described in Section 5.3. This includes methods to access and change all operational parameters in the motion control cards, system database, and root operating system. The software shall support an initialization process to return the system to default operating parameters. 5.6.2. System Database The Dome system shall include a complete database of operating parameters and log of critical events. The database shall include a baseline set of parameters as well as current operational default parameters that have been altered by the user. The system will constrain the operational changes to be bound within safe limits and will not accept out of bound parameters. These parameters include velocities, accelerations, and set points. For safe operation and reasonable diagnostic opportunities the Dome system shall include a database to log critical faults for later review. 5.6.3. System Diagnostics The Dome system shall be capable of self-diagnostic checks of all system components consistent with the operational modes described in Section 1.4. These checks shall be implemented at operator command or automatically, consistent with the operational states of the system. 5.7. Soft Travel Limit As a part of the safety system each shutter shall have software definable limits of travel for each direction of motion. These adjustable set points shall restrain the system from traveling beyond the set limits and will initiate a controlled stop upon approaching these limits. The system shall remain fully operational at these limits but motions are to be restricted to depart from the limit condition. 5.8. Reduced Speed Operation The Dome system shall support the ability to enter a preset slow operation upon the receipt of a SOAR provided signal. The system will be fully functional during this condition but all system motions shall be constrained to a preset slow maximum velocity. The reduced speed shall be in effect when the crane is in use or out of the stowed position. 5.9. Emergency Stop System The Dome control system shall include an appropriate hard-wired point in the system to connect with the SOAR Emergency Stop (E-stop) System. The SOAR E-stop system will be mushroom panic switches distributed throughout the facility to enable an immediate stop of all equipment within the facility. Immediate stops will be necessary if personnel anticipate collisions, smell or 23 DSP99-013

SOAR Dome Specification see smoke, hear inappropriate noises, etc. The connection point for the E-stop system in the Dome control system shall be at a sufficient depth in the system to immediately disable power to all subsystems upon receipt of the signal and without governing by software systems. No subsystem shall be damaged by the activation of an emergency stop. 6. THERMAL REQUIREMENTS 6.1. Dissipated Power Heat producing components located in the Dome can perturb dimensions of the telescope or adversely affect optical seeing. When possible heat producing components shall be located in other areas of the facility. Heat producing equipment that is located within the Dome shall meet the following requirements: 6.1.1. Electronics within the Observing Environment Systems that must be in close proximity to the Telescope and will hence occupy regions of the telescope enclosure shall not dissipate more than a total of 100 watts to the environment in any operational state. In the event that the components would do so, heat removal measure must be taken. The Contractor shall provide insulated housings and suitable cooling heat exchangers, fans, etc for equipment within the fixed enclosure to reduce dissipated power to the specified level. SOAR shall provide suitable flows of ambient temperature glycol/water coolant at the locations of such systems. The Contractor shall provide insulated housings and means to duct the warm air away from the telescope viewing path for such equipment located on the rotating Dome. 6.1.2. Electronics within Other Regions of the SOAR Facility Other electronics systems may dissipate power at nominal industrial rates consistent with use in institutional environments. Facility locations and conditions for these electronics are described in Section 7. 6.2. Thermal Sensing, Control, and Conditioning of Dome Assemblies The objective is to maintain telescope optical surfaces during observing within 0.6 to +0.2C and to minimize heat dissipated to the observing environment, in particular near or in the optical path. 6.2.1. General Thermal Conditioning Strategy The observing environment is serviced by high capacity glycol/water air conditioning systems. This system is specified to maintain the observing environment at the average expected nighttime temperature throughout the day. As the evening approaches, the set point of this system will be adjusted to approximately 1 to 5C below expected ambient temperature. This temperature will be maintained for several hours to allow the observing environment and telescope to equilibrate. Set point is predicated in part on the dew point, expected thermal/time gradient, experiential data, etc. At the onset of observing the air conditioning will be switched off and the facility downdraft ventilation system turned on. This system is capable of up to 30 air changes per hour that provide observing area flushing to equilibrate temperatures in the observing optical path to ambient and dissipate convected heat, providing optimal optical seeing. 24 DSP99-013

SOAR Dome Specification

6.2.2. Actuators & Mountings The Contractor shall minimize the heat capacity and thermal mass of all Dome components in pursuit of the best rate of equilibration. If necessary, components shall be insulated to reduce response to transient ambient thermal conditions. Actuators, sensors, electronics, and other active heat producing components shall be selected to offer minimum dissipated power. To the extent the duty cycle and control bandwidth permits and to the extent practical, actuators shall be designed to provide power-off hold of position and/or force. 7. SOAR FACILITY The SOAR facility is located at 30.233 latitude south. The SOAR facility that will house the Mount structure and its subsystems is shown in Appendix D. This section describes the conditions and locations for various parts of the facility that can be used by the Dome support systems. 7.1. Observing Area The observing area is that space where the Telescope resides. This space consists of the volume surrounded by the 9-meter radius silo and the Dome. This space is air conditioned throughout the day to stay close to the anticipated outside temperature at the onset of observing the following evening. This space is then open to the outside conditions throughout the night, 365 nights a year, weather permitting. The observing space will only be conditioned with a chilled glycol system. No heaters are provided. All equipment housed within the Observing area shall have restricted heat dissipation as defined in Section 6. 7.2. Control Room The facility will have a control room in the control and service building. This space will be maintained with heat and cooling to maintain a standard building environment. The temperatures will be maintained from 15 < T < 25C. 7.3. Computer Room Directly adjacent the Control room will be a computer room designated to house all SOAR control computers. Local computers for the user interface will also be housed in the computer room. Computers are expected to have appropriate keyboard, monitor, and mouse extenders, as necessary to allow the separation of these parts from the main computer and power supplies. The computer room will be fully air conditioned within a temperature range of 18 < T < 23C. 7.4. Mechanical Equipment Building The SOAR facility includes a mechanical equipment building located at the southern end of the control and service building. This room is intended for all equipment that is loud, heat producing, and/or operates with vibration. This room is separated to allow a separate foundation for vibration control, space for sound control, and distance to put large heat sources as far from the telescope as possible. This building will have waste heat exhaust fans directed to the down wind side of the mountain. This room will not be temperature-controlled, except for heating as locally required by equipment. The achievable range of local temperature control will be 10 < T < 35C. Space in the equipment building is available to be allocated to SOAR subsystems as needed. 25 DSP99-013

SOAR Dome Specification 7.5. Instrument Utility Room Within the lower level of the cylindrical telescope silo building will be a separately enclosed space for instrument utility equipment. This room (approximately 12m2) will house the compressors, chiller(s), tanks, pumps, etc. that are smaller scale, produce less heat than the large mechanical equipment, and benefit from close proximity to the telescope and instruments. The space will be insulated and vibration isolated from the rest of the enclosure. Similar to the Mechanical Equipment Building, this space will be temperature controlled only with local heating as specifically required for equipment with a range of 10 < T < 35C. 7.6. General Facility Space There is significant additional space within the SOAR facility that has been designated for general use. Space can be allocated, as needed, to SOAR subsystems upon request. The general space within the facility is neither heated nor cooled and thus experience temperatures as described by the Environmental Survival conditions. 7.7. Intra-Facility Distances Table 7-1 defines the distances (10%) for cables and utilities that interconnect between various locations within the facility. The maximum distance is used for the Dome drives. All cables run through cable trays in the lower level of the facility. From: Dome Drive Dome Drive Dome Drive Dome Drive Control Room Control Room Control Room Computer Room To: Control Room Computer Room Mechanical Room Instrument Utility Room Computer Room Mechanical Equipment Room Instrument Utility Room Instrument Utility Room Distance (meters): 50 50 45 26 12 21 24 28

Table 7-1 Facility to Observing Level Cable Distances

7.8. SOAR Supplied Utilities SOAR will supply a water/glycol coolant fluid flow to any location within the facility required for equipment cooling to ambient conditions. SOAR will also supply power to all required locations within the facility. Power is defined previously. Lines will be terminated with an appropriate manual cut off switch consistent with the power provided. A supply of compressed air is also available throughout the facility. This air will be 827kPa (120 psi), have a nominal flow rate of 0.6 Standard Cubic Meters/Min (20 SCFM) and have general filtering. Components requiring special conditions will need to include the necessary processing. 8. INSTALLATION The Dome shall be designed and fabricated for on-site assembly. The internal steel structure shall have bolted joints to allow pre-assembly for test at the Contractors facility. After testing 26 DSP99-013

SOAR Dome Specification the structure shall be disassembled for shipping. The Contractor shall provide technical support for assembly and debug of the Dome at the Telescope facility. 8.1. Site Installation The Dome is designed with bolted joints between major substructures to allow fast assembly at the SOAR site. The bogies and Dome drives shall be installed on the facility silo while a temporary roof is in place. The internal steel structural frame shall be assembled next to the facility. The shutters may be installed at this time. To the extent possible, part of the panel system should be installed before lifting the internal structure frame onto the facility. The remaining panels shall be assembled in two to three sections with appropriate lifting lugs to be used to rapidly lift and aid assembly on the internal steel frame. A preliminary sequence of installation is described here: Initial installation of the bogies and drive assemblies shall be accomplished using suitable cranes and lifts without the Dome in place. The Dome is partially assembled next to the facility, the temporary roof is removed, and the partially assembled Dome will be lifted and emplaced on the stationary bogies. The panel system will be lifted in sections and attached to the internal structure. The final installation plan shall be defined by the Contractor and SOAR as described in the SOW and this specification. The Contractor shall provide technical support as defined in the Statement of Work. 8.1.1. Dome Bogies and Drive The facility will have a temporary roof to provide protection during the bogie and drive installation. The bogies are aligned with the each other at assembly. Alignment shall be accomplished with laser alignment equipment. A level plane shall be defined to locate the rotating surface of the Dome defined by the top of the bogie wheels. The angular alignment of the bogies with respect to the center of rotation of the Dome shall be within the specified values. 8.1.1.1. Bogie Alignment Camber Alignment: 2 Steering Alignment: 2 arcmin

After alignment the bogies are grouted in place. The Dome drives shall be emplaced on the fixed facility and leveled. Final location and anchoring of the drives is performed after installation of the ring beam. 8.1.2. General Sensors Installation of the general sensors shall be determined during Detailed Design. The Contractor shall specify an installation method and materials appropriate to the sensor design. 9. ENVIRONMENTAL CONDITIONS The SOAR Telescope site is located at elevation 2,700m (8,860ft) on Cerro Pachn, Chile. Radiation from the sun shall be included in the determination of the choice of materials for the 27 DSP99-013

SOAR Dome Specification Dome and panel system. All loads, live loads, ice / snow loads, wind loads, and temperature effects shall be combined per ASCE 7-88 Standard or equivalent when determining the critical cases for stress and deflections. 9.1. Operating Conditions The following data represents the range of environmental conditions during operation. All Dome systems must be fully functional during the worst case combination of these conditions. The depression temperature is the temperature to which an exposed object will cool through radiation to the nighttime sky. Wind Speeds: Temperature: Relative Humidity: Maximum Uniform Ice Build-up: Depression Temperature: < 20m/s (66.6ft/s) with 25m/s gusts (82ft /s) -10 to +25C (+14 to +77F) 5% to 95% 25mm (1.0in) or 22kg/m2 (4.7psf) -25C (-13F)

9.2. Survival Conditions The following data represents the range of non-operating environmental conditions the Dome is required to withstand. The Dome shall be in the fully closed stationary configuration when considering worst case combination of these conditions. Wind Speeds: Temperature: Maximum Diurnal Temperature Difference: Snow Loading on Projected Horizontal Surface Area: Additional Uniform Ice Build-up On Exposed Surfaces Not Covered with Snow: Range of Annual Precipitation1: Design Precipitation Event: Seismic Ground Acceleration:
1

67m/s gusts (220ft/s) -25 to +30C (-13 to +86F) 30C (54F) 170kg/m2 (35psf)

25mm (1.0in) or 22kg/m2 (4.7psf) 11.4mm to 487mm (0.45 to 19.2in) 25mm/h (1.0in/h) with 30m/s (98.4ft/s) wind Zone 4 Requirements per the Uniform Building Code

Information shown is from nearby CTIO, during the time period spanning 1965 to 1992 DSP99-013 28

SOAR Dome Specification

10. GENERAL STATUS AND SENSING SYSTEM The Dome system shall include various status and general-purpose sensors to monitor system health, subsystem condition, and performance. All sensor signals shall be provided to the control system and shall be accessible from the TCS and Dome Terminal. In addition to the sensors identified in other sections of this specification the following general-purpose sensors shall be provided. 10.1. Sensors After site integration, SOAR will install various environmental sensors in the Dome. To support this effort, the contractor shall provide expansion slots in the dome and shutter controller for data acquisition cards. The number of slots shall be based on the requirement to install twenty (20) sensors on both the dome and the shutter. 11. SAFETY The Dome shall include safety systems to prevent personnel injuries or equipment damage. The Contractor shall submit a safety analysis and plan at least 1 month prior to the Acceptance Testing of the Dome. All elements of safety covered under this section shall be incorporated into the plan, as well as additional elements the Contractor may wish to add. 11.1. Over Speed Protection All drives shall include a monitor that removes power and applies the fail safe brake when an over speed condition is detected. The protection shall be in the drive control system. The over speed limit shall be consistent with the design of the drive system to prevent damage to the drive or the Dome. 11.2. Over Current Protection All drives shall include over current protection. If the drive is stalled for any reason power shall be removed from the motor and the fail-safe brake applied. The time required to remove power shall be consistent with the design of the drive system to prevent damage to the drive or the Dome. 11.3. Interlock Procedures 11.3.1. Dome and Shutter Drives All drives shall be interlocked with a safety switch at the aerial man-lift park position. The Dome and shutter drives shall be disabled or limited to reduced-speed operation when the man-lift is in operation. The SOAR Project will provide the Dome Contractor with technical information regarding this switch and the interlock at the beginning of work. 11.3.2. Aerial Man-lift Personnel operating the aerial man-lift shall be checked out and authorized for such operation by Site personnel prior to man-lift operation.

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SOAR Dome Specification 11.3.3. Dome Crane The Dome crane shall have safety interlocks that provides a signal to the TCS that the crane is or is not in the stow position. The Dome shall rotate at reduced speed when the crane is out of the stowed position. 11.4. Captive Tools and Fasteners Every effort shall be made in the Dome design to minimize the use of tools for overhead maintenance. When tools must be used for servicing and maintenance, they shall be secured by lanyards to the servicers tool belt or the man-lift. All fasteners, covers panels, and other components which can be accessed shall be captivated by the use of turn captivated fasteners, wire loop, bails, threads, or some similar means. No lock washers shall be used for accessible fasteners above the telescope. Chemical locking compounds or aircraft-type locking nuts shall be used instead. 11.5. Mirror Cover The mirror cover shall be closed to cover the primary mirror (M1) prior to any overhead servicing or moving the man-lift within the facility. A cover shall be installed on the tertiary mirror (M3) prior to any overhead work. 12. COATINGS All surfaces of the Dome shall be treated with a protective coating as per the specification provided in Appendix A. An epoxy enamel paint system over primer shall be used on all non moving contact metallic surfaces. The color and paint system selected by the Contractor shall be approved by SOAR. Drive surfaces, bearing tracks, or surfaces that provide for moving contact shall not be painted. Unpainted surfaces shall be protected from corrosion by appropriate choice of materials or coatings. Radiation from the sun consistent with the location of the Telescope site shall be considered when choosing external coatings. 12.1. Internal Coatings The color of the final coat shall be a diffuse gray.

12.2. External Coatings The color of the final coat shall be white. 13. RELIABILITY AND MAINTAINABILITY REQUIREMENTS The SOAR facility shall be used 365 nights a year. The objective of the facility is to allow the maximum telescope use and quality for the given weather conditions on any night of the year. The remote nature of the site puts further premium on having robust systems that are easily repaired.

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SOAR Dome Specification 13.1. Duty Cycle The Dome shall be capable of operating 350 nights a year, at a maximum frequency of 25 full travel cycles for Dome rotation, shutter, and windscreen. Half of these cycles shall be at maximum velocity, half at 10% maximum velocity. 13.2. Mean Time Between Failure (MTBF) The MTBF for the Dome shall be designed to be no less than 5,000 hours, or approximately once every two years. 13.3. Design Life The design life of the Dome shall be 20 years. Friction and wear components not expected to provide reliable performance over such a life span shall be easily inspected and replaced. Servicing instructions shall include inspections of such equipment to evaluate conditions on a periodic basis. Structural fatigue shall be considered in the design due to the long design life. 13.4. Routine Servicing All routine servicing shall be specified and provided with the final documentation. All routine servicing and general maintenance shall be designed so as to take no longer than eight hours. A normal daytime shift. 13.5. Access Panels As required, removable access panels shall be located on the Dome for servicing of all drives, bearings, and tracks. All panels shall be attached using captivated hardware. External access is necessary for the shutter track and bogie assemblies. These access panels shall be located at each end of travel and, at a minimum, two locations of intermediate travel. As required, additional access for other subsystems shall be determined during the design phase. 13.6. Critical Spares The Contractor shall perform a critical risk analysis during the detailed design phase and provide a list of critical spare parts to the SOAR Project for timely procurement. 13.7. Modularity The Dome subsystems shall be organized into modules for the ease of installation and servicing. Particularly any components that have critical alignments that would be easier to achieve in the work area and then placed on the Dome. Parts that have critical alignments shall be mounted with adjustment screws and subsequent locking mechanisms to facilitate initial and subsequent alignments. 13.8. Special Tools and Equipment The contractor shall provide all special tools and equipment necessary for initial set-up, maintenance, and servicing operations. All imperial tooling shall be considered special tools. This excludes common hand tools such as screwdrivers, wrenches, sockets, Allen keys, etc. Custom stands, sights and instruments necessary for initial set-up of the system, debug, and regular maintenance shall be delivered as special tooling and equipment. Any special handling fixtures, spreader bars, and lifting hardware necessary for handling parts of the Dome shall be deliverable with the Dome. Special tools shall be marked with the part number. 31 DSP99-013

SOAR Dome Specification

13.9. Lifting points All major subassemblies and substructures of the Dome shall include lifting lugs to allow proper handling during initial assembly and subsequent possible removal. Jacking points on subassemblies shall be included where necessary for maintenance. The internal steel structural frame shall be assembled next to the facility. The shutters shall be installed at this time. To the extent possible, part of the panel system should be installed before lifting the internal structure frame onto the facility. The remaining panels shall be assembled in two to three sections with appropriate lifting lugs to be used to rapidly lift and aid assembly on the internal steel frame. 13.10. Lifting Fixtures Special lifting fixtures that are used for installation and are required for maintenance shall be designed, documented, fabricated and delivered with the Dome. 13.11. Quick Release Attachments Attachment points, such as eye bolts, shall be located at several external locations on the arch girder. The attachments shall be sealed to prevent water from entering the Dome. These attachments are used for securing safety cables during external maintenance operations. The cables or ropes will be similar to the types used for mountain climbing with quick disconnects. 13.12. Dome Drive Lifting Points Lifting lugs shall be located on the arch girders a radial location coincident with the dome drives. The Dome is rotated to position the lug over the drive to be serviced. These lugs are used to attach Contractor designed lifting hardware used to remove the drive assembly during maintenance operations. 14. ACCEPTANCE TESTING The Contractor shall provide an Acceptance Test Plan and Verification Matrix. To the extent possible, the Dome shall be acceptance tested as a fully integrated assembly at the Contractors site. The panel system shall not be installed but the mass and inertia is simulated through appropriate test mass. SOAR will provide a computer to simulate the Telescope control system operation. These tests shall be satisfactorily performed to demonstrate compliance with the stated requirements in this Specification prior to Dome acceptance. 14.1. Required Tests The tests shall include full Dome drive operation, shutter operation, crane operation under normal and emergency operating conditions. The tests shall verify the performance requirements in this Specification. The bogies and Dome drives shall be installed in an assembly similar to the final installation. The internal frame, with shutter door frames and drive, shall be assembled and placed on the bogies. The slip rings shall be installed on the Dome and the shutter. Appropriate test masses shall be attached to the structure and shutter doors to simulate the mass properties of the fully assembled Dome under the environmental operating conditions. The main concern is to reproduce the friction and wind loading between the bogies, drives, shutters, and Dome. 32 DSP99-013

SOAR Dome Specification 14.2. Test Standards All equipment and standards used in acceptance testing shall be calibrated and traceable to established standards to ensure accuracy and integrity of testing. These tests shall be satisfactorily performed to demonstrate compliance with the stated requirements in this Specification prior to the Dome acceptance. Failure to meet all acceptance test requirements to the satisfaction of the SOAR Project shall result in rework or other corrective actions by the Contractor until the subject requirements are met. 14.3. Test Masses Test masses shall be fabricated to replicate the Dome assembled mass properties under normal environmental operating conditions defined in this Specification. These test masses shall be installed on the Dome during all performance and acceptance testing. The test masses are not deliverable items. 14.4. Cabling and Hoses The final deliverable cables and hoses shall be used in all acceptance testing. 15. PACKAGING AND SHIPPING The Dome shall be disassembled into a minimum number of parts and subassemblies after completion of acceptance testing at the Contractors facility. The parts and subassemblies shall be packaged in appropriate shipping containers and transported to the Telescope site. It may be advantageous for some subassemblies to remain in their integrated form that will not fit in a container. These subassemblies shall be packaged to survive shipping and will be considered on a case by case basis. 16. DOCUMENTATION The following documentation shall be provided at the completion of acceptance testing at the Contractors facility unless noted otherwise in this specification or the Dome SOW.

16.1. Operation Manual An Operation Manual shall be provided with the Dome detailing the operator inputs that are required to achieve normal and diagnostic mode operation of the Dome. 16.2. Servicing Procedures Servicing procedures, including troubleshooting techniques shall be provided within three weeks of the Dome acceptance. The procedures shall also include all technical information provided by sub-component manufacturers, consumable servicing materials specifications (e.g. grease, oil, etc), as well as clearly written disassembly/assembly instructions for the major components of the Dome. The procedures shall include a list of all special tools and additional support equipment required. The list shall reference where used. A servicing schedule for components requiring regular maintenance shall be provided. 33 DSP99-013

SOAR Dome Specification

16.3. Test Results / Benchmarks Final test results and benchmark quantities shall be recorded and provided with the Acceptance Test Results. Such quantities characterize the Dome performance at the Contractors facility, and will be used as a baseline for maintenance checks. 16.4. Operations Log An Operations Log shall be maintained beginning when the Dome or major subsystems first start trial operations at the Contractors facility. The Log shall record the dates the Dome or major subsystems were operated, by whom, and with what purpose (e.g. routine maintenance tests, troubleshooting, etc). In addition to recording the routine information, any unusual, unexplained, or unpredicted motion or condition observed shall be recorded in the Log. SOAR personnel shall assume responsibility for maintaining the Log following delivery and installation of the Dome to the site. 16.5. Safety Plan / Procedures A Safety Plan/Procedure shall be provided within three (3) weeks of Dome acceptance. The plan shall include precautions specific to Dome installation, maintenance, general safety requirements, and safety equipment required. This document can be included as a section in the Servicing Procedures if desired by the Contractor. 16.6. Documentation Within two weeks of successful Acceptance Test, the Contractor shall supply full-size copies of all drawings, a drawing tree, software listings, as built specifications and drawings, component specifications, literature, and manuals; electrical schematics, layouts, interconnection lists, and cable descriptions; analysis files (computer generated and classical), and all current CAD format files, on CD, associated with the final Dome configuration. 16.7. Installation Procedures The Dome Contractor shall provide a detailed procedure for unpacking, installation, debug, and testing of the Dome on-site after delivery.

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SOAR Dome Specification

APPENDIX A

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APPENDIX A SOAR APPLICABLE STANDARDS AND SPECIFICATIONS General: The following standards are the general specifications for the design, fabrication and integration of all SOAR components and subsystems. Equivalent Brazilian or international standards may be substituted to facilitate design and fabrication. Published standard specifications and/or codes are referred to by the following abbreviations: (In the case of conflict between the published standards, the standard affording the most protection to the SOAR Project shall prevail. In the case of conflict between a standard and this document, this document shall prevail.) Contractor substitution is permitted to obtain improved performance or reduced cost is subject to written approval by the SOAR Project. 1. ABBREVIATIONS AISC American Institute of Steel Construction AISC Manual of Steel Construction, 9th ed. AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings. Latest edition with the latest revisions. ANSI ASCE ASTM AWS American National Standards Institute American Society of Civil Engineers American Society for Testing and Materials American Welding Society AWS D1.1-92 Structural Welding Code Steel, with latest revisions. Steel Structures Painting Council Good Painting Practice, Steel Structure Painting Manual Vol.1 Systems and Specifications, Steel Structures Painting Manual Vol. 2 Uniform Building Code, 1994 Division III-EarthQuake Design

SSPC

UBC

2. WORKMANSHIP 2.1. Fabrication and Assembly Fabrication and assembly is to be performed in accordance with AISC Specification of the Design, Fabrication, and Erection of Structural Steel for Buildings, latest edition with latest

SOAR Dome Specification revisions. An alternate standard for standard fabrication practice may be substituted with SOAR approval. 2.1.1. Welding Welding is to be performed in accordance with the above AISC specification, as well as with AWS D1.1-92 Structural Welding Code Steel, with the latest revisions. An alternate standard for welding practice may be substituted with SOAR approval. 2.1.2. Stress Relieving Stress Relieving is to be performed in accordance with Section 4.4 of AWS D1.1-92 (above) for stress relief by heat treatment; or as approved by the SOAR Project. Vibratory stress relieving is allowed as approved by SOAR. 2.1.3. Edges All metal edges shall be free of burrs and sharp corners. No sharp edges that might constitute a hazard to personnel shall remain on the finished components of the Dome. 3. MATERIALS The following are the specifications for the common materials required for fabrication of the SOAR Dome. Materials specified by the Contractor shall be consistent with all requirements including life cycle, reliability, and maintainability. Substitution is permitted to obtain improved performance or reduced cost subject to written approval by SOAR only. 3.1. Material Certification Material certification is required for all major structural materials. The Contractors shall submit evidence to SOAR that the mill or fabricator has complied with the requirements contained in this section and/or the specifications established by the Contractors design as approved by the SOAR Telescope Project. 3.2. Structural Steel All hot rolled steel plates, shapes, sheet piling, and bars shall be new steel conforming to ASTM Specification A6 Standard Specification for General Requirements for Rolled Steel Plates, Shapes, Sheet Piling, and Bars for Structural Use or equivalent international standards. 3.3. Structural Steel Shapes, Plates, and Bars Carbon Steel, ASTM A36 Standard Specification for Structural Steel. ASTM A36, except where different, fabricated components or shapes are specified by the Contractors design as accepted by the SOAR Telescope Project. 3.4. Round Steel Pipe ASTM A53, Grade B. 3.5. Square and Rectangular Tubing ASTM A501.

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SOAR Dome Specification 3.6. Structural Bolts and Threaded Fasteners Structural bolts and threaded fasteners shall comply with the following ASTM specifications as appropriate for the types and at the locations as specified on the drawings: 3.6.1. ASTM A325 Type 1 High-Strength Bolts for Structural Steel Joints. No galvanized bolts shall be used. 3.6.2. Threaded Round Stock ASTM A36. 3.6.3. Bolts and Nuts, High Strength Bolts Bolts and nuts for all high strength bolts shall be heavy hex head conforming to ANSI. Standards B18.2.1 and B 18.2.2 respectively. Nuts shall conform to ASTM A563, Standard Specification for Carbon and Alloy Steel Nuts or equivalent international standards. 3.6.4. Washers All washers shall be circular, flat and smooth and shall conform to the requirements for Type A washers in ANSI Standard B 23.1. Washers for high strength bolts shall be hardened and conform to ASTM F 436, Specification for Hardened Steel Washers. Beveled washers for America Standard Beams and channels shall be square or rectangular and taper in thickness (16 2/3% slope) with an average thickness of 5/16. When an outer face of a bolted part has a slope greater than 1:20 with respect to a plane normal to the bolt axis, a beveled washer shall be used. Equivalent international standards are acceptable. 3.6.5. Stainless Steel Bolts and Nuts Stainless Steel bolts, nuts, and washers shall comply with ASTM F837 for high strength applications and ASTM 582 for standard use or equivalent international standards. 3.6.6. Load Indicator Washers Field Bolting: All field bolting of high strength friction bolts shall use load indicator washers such as Coronet Load Indicators as manufactured by Cooper and Turner or Bethlehem Load Indicator Washers as manufactured by Bethlehem Steel Corp. Shop Bolting: All shop bolting of high strength friction bolts shall use load indicator washers as specified above or load indicator bolts such as LeJeune Bolts as manufactured by LeJeune Bolt Company or Load Indicator Bolts as manufactured by Bethlehem Steel Corporation. 3.6.7. Bolt Lubrication: All bolts shall be well lubricated at the time of installation. Dry, rusty bolts will not be allowed. Bolts or nuts shall be wax dipped by the bolt supplier or Johnsons Stick Wax 140 or similar material shall be used with all bolts in the shop or field. 3.6.8. New Bolts All new bolts, washers, and nuts shall be used for assembly of the system. New bolts shall be procured and installed per the AISC specification above. A-38 DSP99-013

SOAR Dome Specification 3.7. High Strength Bolting 3.7.1. Applicable Specifications and Procedures Assembly and tightening of all bolted connections shall be performed in conformance with AISC specification Structural Joints using ASTM A325 and A 490 Bolts and in Section 3.6.3 above. Procedures, tolerances, and requirements for surface preparation, installation, use of hardened and load-indicating washers, alignment of member surfaces, tightening, and inspection are clearly called out in the above specification and shall be adhered to by the Contractor. Oversize, Short-slotted and Long-slotted Holes: The dimensions and washer requirements of oversize, short slotted, and long slotted holes shall conform to the high strength bolting specification previously cited. Tightening of High Strength Friction Bolts by use of a Direct Tension Indicator: All field -bolting of high strength friction bolts shall use load indicator washers with hardened washers as specified by the manufacturer. Shop bolting of high strength friction bolts shall use load indicator washers as specified above or load indicator bolts. 4. WELDING The following standards and specifications shall apply to all welding: 4.1. Electrodes Shall be compatible with the parent metal joined. 4.2. Welding Electrodes General: ASTM A233 AWS 501, and classification numbers and sizes as recommended by AISC and AWS for the specific material and use. 4.3. Electrodes for Welding Comply with AWS D1.1, Structural Welding Code Steel. Electrodes for various welding processes shall be as specified below: SMAW: SAW: GMAW: FCAW: E70XX low hydrogen FF7X-EXXX ER70S X E7XT-X

4.4. Applicable Codes and Standards All Welding is to be carried out in accordance with the provisions of AWS D1.1-92, Structural Welding Code and AISC Specification for the Design, Fabrication and Erection of Structural Steel for Buildings, latest edition.

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SOAR Dome Specification 5. PAINTING AND CORROSION CONTROL General: Without limiting the general aspects of other requirements of these specifications, all surface preparation, coating and painting of interior and exterior surfaces shall conform to the applicable requirements of the Steel Structures Painting Council and the manufacturers printed instructions. All metallic surfaces which will remain exposed to air when the components are assembled into the SOAR telescope Dome shall be finished, either prepared and painted or passivated by another process such as anodizing, oxides, or irridite. The process for surface treatment will be specified by the Contractor, consistent with the recommendations of the paint or process manufacturer, and approved by SOAR. Following approval of a process by SOAR the Contractor will not deviate from the approved process without prior approval by SOAR of the change. For external portions of the Dome, the intent is to provide surfaces that will not corrode, can be easily cleaned, and are cosmetically pleasing. SOAR reserves the right to choose the colors that will be applied from a range of options to be provided by the Contractor. All unpainted mating surfaces that are exposed to the air during shipping shall be coated with a removable corrosion inhibitor. 5.1. Quality Assurance General: Quality assurance procedures and practices shall be utilized to monitor all phases of surface preparation, application and inspection throughout the duration of the project. Procedures or practices not specifically defined herein may be utilized provided they meet recognized and accepted professional standards and are approved by SOAR. Surface Preparation: Surface preparation will be based upon comparison with Pictorial Surface Preparation Standards for Painting Steel Surfaces SSPC-Vis-1 and ASTM Designation D2200; and Visual Standard for Surfaces of New Steel Airblast Cleaned and Sand Abrasive. Application: No coating or paint shall be applied under the following conditions. When the surrounding air temperature or the temperature of the surface to be coated or painted is (a) below the minimum surface temperature for the products specified herein or (b) too wet or damp less than 2.7C (5F) above the dew point, or (c) when the air temperature is expected to drop below specified minimum temperature within six hours after application of coating. If above conditions are prevalent, coating or painting shall be delayed or postponed until conditions are favorable. The days coating or painting shall be completed in time to permit the film sufficient drying time prior to damage by atmospheric conditions. 5.2. Safety and Health Requirements General: In accordance with requirements set forth by regulatory agencies applicable to the construction industry and manufacturers printed instructions and appropriate technical bulletins and manuals, the Contractor shall provide and require use of personal protective lifesaving equipment for persons working on or about the project site. 5.3. Surface Preparation Near White Blast Cleaning (SSPC-SP10): The removal of all visible oil, grease, dirt, dust, mil scale, rust, paint, oxides, corrosion products and other foreign matter by compressed air nozzle blasting, centrifugal wheels or other specified method. Discoloration caused by certain stains A-40 DSP99-013

SOAR Dome Specification shall be limited to no more than 5% of each square inch of surface area. Mil profile 1.0 2.0. All welds shall be neutralized with a suitable chemical compatible with the specified coating materials. 5.4. Painting Sequence Primer coats shall be applied at the fabrication facility immediately after blast cleaning and prep. Painted areas shall have been blast cleaned the same day. Subsequent coats shall be applied within one week or other time period as indicated by the paint manufacturer. 5.5. Exceptions to Painting Requirements Machined Surfaces: On pieces that contain machined surfaces specifically for mating to other machined or non-machined surfaces, those surfaces are to be left unpainted, and are to be coated with a preservative such as light machine oil and wrapped with a durable waterproof wrapping. All unpainted mating surfaces that are exposed to the air during shipping shall be coated with a removable corrosion inhibitor. Stainless steel shall be left unpainted. The Contractor may request relief from painting other areas of the structure if to do so yields a performance benefit. Such request shall take place during Detailed Design. The Contractor may propose alternate standards and processes for painting or other surface finish treatments as appropriate to the materials used and the overall objectives of the SOAR performance and environmental conditions. 5.6. Contamination and Cleaning Surface finish treatments and hardware selected by the Contractor for the Dome shall not generate particles that may contaminate optical surfaces. Finishes shall be compatible with a cleaning process to be defined by the Contractor consistent with the recommendations of the finish supplier.

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APPENDIX B

COMPONENT SPECIFICATIONS

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SOAR Dome Specification

APPENDIX C

DESIGN DRAWINGS

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APPENDIX D

REFERENCE DOCUMENTS

APPENDIX E

PANEL SYSTEM SPECIFICATION

SOAR Dome Specification

1. PURPOSE This specification covers the design, fabrication, and erection of the Dome panel system for the SOAR Telescope Project. 2. SCOPE This specification defines the structural, mechanical, environmental, and assembly requirements for the installed dome panel system, nesting shutter doors, the interface with the Dome structure, and utilities. In addition, all requirements in the Dome Specification apply to the panel system. 3. BACKGROUND The Dome is for the SOAR Telescope Project. The telescope is a 4.2 meter altitude-azimuth design. The Dome will be erected on Cerro Pachon, Chile. 4. DOME SYSTEM DESCRIPTION 4.1. General The Dome is a 5/8 portion of a 10-meter outside diameter sphere. Twin steel arch girders and a steel base ring beam structurally support the panels. The arch girders also support the nesting double shutter system as well as a facility crane. The term Panel System refers to the insulated monocoque structure, completely self-supporting, and requiring no internal or external support structure. Each spherical panel includes integral, flush mounting points. The Panel System regions, as shown in Figure 4.1, will be fully supported around boundary edges by the arch girders and base ring. The Panel System is required to support Dead, Live, Wind, and Ice / Snow loading spanning between primary framing supporting members. A stiffened smooth spherical or geodesic type paneling system is envisioned. 4.2. Fixed Dome The fixed Dome area is the 5/8 sphere minus the shutter opening and is determined by the ring beam, and arch girders. The fixed Dome area is defined in Figure 4.1. 4.3. Shutters The shutters are rectangular portions of the sphere. The shutter panel area is shown in Figure 4.2. The shutter sizes and interfaces are defined by the drawings provided in Appendix C. 4.4. Vents 2.7m2 of ventilation area shall be provided at the top of the Dome. Standard weatherproof mushroom type hoods shall be provided to prevent the intrusion of precipitation, including rain, ice, and snow. A grill mesh shall be incorporated to prevent large insects and fowl access into the dome interior. Four (4) Greenhech Model GRS-36 gravity vents ,or equivalent, are required on the top of the Dome panel system. The vents shall include Greenhech VCD-23 powered back draft louvered dampers or equivalent. Limit switches shall be installed to the E-46 DSP99-013

SOAR Dome Specification dampers to sense opened and closed positions. All cabling and attachments shall be the responsibility of the Panel Contractor. Power and control of the dampers shall be provided by the Dome Contractor. The vents shall be attached to curbs on the panels system. The attachment area shall be weatherproof. Proper vertical orientation of the vents shall be considered in the mounting. 4.5. External Ladder Attachment An external ladder shall be attached on each side of the arch girders. The ladder will be used for servicing the shutters. The ladder will be enclosed in a cage as required by local standards. The location of the ladder shall be coordinated with SOAR. 4.6. Internal Lighting Attachment Provisions shall be made for attaching three (3) light fixtures on the internal surface of the panel system. Attached conduit shall be included with the panels. The light fixture locations and conduit routing are shown on drawing ED4. The light fixture are specified in Appendix B of the Dome Specification 4.7. Lighting Protection Lighting protection system shall be included in the panel system. The Contractor shall provide all lighting arrestors, mounting for the lighting arrestors and cabling located on the panel system. The mounts shall be internal with the arrestor protruding through the panels. A sealing method shall be included in panel. Cabling for the system shall be routed and attached inside the Dome on the panels. Arrestor locations and cable routing is shown on drawing ED1. A lighting analysis shall be performed by the Contractor to define the location, type, and quantity of the lighting arrestors on the Dome. The installation and design of the system shall meet the Lightning Protection Institute (LPI) Code 175 and National Fire Protection Association (NFPA) 780. Installation shall be made by or under the supervision of an LPI certified master installer. Complete installation to receive system certification including submittal of forms LPI 175-A and 175-B. 5. REQUIREMENTS 5.1. General The Contractor shall minimize the total weight of the panel system. The system shall minimize the loads transferred into the two arch girders. Optimally, the Dome panel system is selfsupporting and adds stiffness to the overall Dome assembly without increasing the Dome weight with additional support structure. The Panel System is required to be watertight, regardless of the direction of water impingement, due wind driven rain. 5.2. Mechanical Requirements The following properties are based on composite panels with a foam core separating the face sheets.

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SOAR Dome Specification 5.2.1. Panel Thickness Maximum: 76.2mm (3 inches) 5.2.2. Core Thickness Minimum: 50.8mm (2.00 inches) 5.2.3. Thermal Insulation R19 Equivalent 5.2.4. System Weight Maximum: 24.5kg/m2 (5psf) 5.2.5. Face Sheet Properties Minimum Thickness: Minimum Modulus of Elasticity (E): 1.02mm (0.040 inches) 1.77 E10 Pa (2.57 E6 psi)

5.3. Environmental Conditions The SOAR Telescope site is located at 30.233 latitude south and elevation 2,700m (8,860ft) on Cerro Pachn, Chile. Radiation from the sun shall be included in the determination of the choice of materials for the panel system. 5.3.1. Operating Conditions The following data represents the range of environmental conditions during operation. All Dome systems must be fully functional during the worst case combination of these conditions. The depression temperature is the temperature to which an exposed object will cool through radiation to the nighttime sky. All loads, live loads, ice / snow loads, wind loads, and temperature effects shall be combined per ASCE 7-88 Standard or equivalent when determining the critical cases for stress and deflections. Wind Speeds: Temperature: Relative Humidity: Maximum Uniform Ice Build-up: Depression Temperature: < 20m/s (66.6ft/s) with 25m/s gusts (82ft/s) -10 to +25C (+14 to +77F) 5% to 95% 25mm (1.0in) or 22kg/m2 (4.7psf) -25C (-13F)

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SOAR Dome Specification 5.3.2. Survival Conditions The following data represents the range of non-operating environmental conditions the Dome is required to withstand. The Dome shall be in the fully closed stationary configuration when considering worst case combination of these conditions. All loads, live loads, ice / snow loads, wind loads, seismic, and temperature effects shall be combined per ASCE 7-88 Standard when determining the critical cases for stress and deflections. Wind Speeds: Temperature: Maximum Diurnal Temperature Difference: Snow Loading on Projected Horizontal Surface Area: Additional Uniform Ice Build-up on Exposed Surfaces not Covered w/Snow: Range of Annual Precipitation2: Design Precipitation Event: Seismic Ground Acceleration: 5.4. Deflections 5.4.1. Dome Paneling System Maximum deflection under worst case load combination = span/240 5.4.2. Shutters Panels Maximum deflection under worst case load combination = span/360 5.5. Interfaces 5.5.1. Structural Steel All panel system interfaces to the Dome structure shall be mutually defined with the Contractor and SOAR. The interface shall account for differences in expansion due to the different coefficients of thermal expansion (CTE) of the materials. To the extent possible the loads shall be evenly distributed into the ring beam and arch girder. All interfaces shall be water tight.
2

67m/s gusts (220ft/s) -25 to +30C (-13 to +86F) 30C (54F) 170kg/m2 (35psf) 25mm (1.0in) or 22kg/m2 (4.7psf) 11.4mm to 487mm (0.45 to 19.2in) 25mm/h (1.0in/h) with 30m/s (98.4ft/s) wind Zone 4 Requirements per the Uniform Building Code

Information shown is from nearby CTIO, during the time period spanning 1965 to 1992. DSP99-013 E-49

SOAR Dome Specification

6. COATINGS All surfaces of the Dome panel system shall be treated with a protective coating as per the specification provided in Appendix A. An epoxy enamel paint system over primer shall be used on all metallic surfaces. The color and paint system selected by the Contractor shall be approved by SOAR. Radiation from the sun consistent with the location of the Telescope site shall be considered when choosing external coatings. Fiberglass panels shall use a gelcoat surface coat. 6.1. Interior Coatings The color of the final coat shall be a diffuse gray. 6.2. Exterior Coatings The color of the final coat shall be white. 7. RELIABILITY AND MAINTAINABILITY REQUIREMENTS The SOAR facility shall be used 365 nights a year. The objective of the facility is to allow the maximum telescope use and quality for the given weather conditions on any night of the year. The remote nature of the site puts further premium on having robust systems that are easily repaired. 7.1. Design Life The design life of the Dome shall be 20 years. Structural fatigue shall be considered in the design due to the long design life. 7.2. Routine Servicing All routine servicing shall be specified and provided with the final documentation. All routine servicing and general maintenance shall be designed so as to take no longer than eight hours. A normal daytime shift. 7.3. Critical Spares The Contractor shall provide a list of critical spare parts to the SOAR Project for timely procurement. 7.4. Modularity The panel system shall be organized into modules for the ease of installation and servicing. The system shall be designed for assembly at the Telescope site. 7.5. Special Tools and Equipment The Contractor shall provide all special tools and equipment necessary for initial set-up, maintenance, and servicing operations. All imperial tooling shall be considered special tools. This excludes common hand tools such as screwdrivers, wrenches, sockets, Allen keys, etc. Custom stands, sights and instruments necessary for initial set-up of the system and regular maintenance shall be delivered as special tooling and equipment. Any special handling fixtures, spreader bars, and lifting hardware necessary for handling parts of the panel system shall be deliverable with the system. Special tools shall be marked with the part number. E-50 DSP99-013

SOAR Dome Specification 7.6. Lifting points All major subassemblies and substructures of the panel system shall include lifting lugs to allow proper handling during initial assembly and subsequent possible removal. To the extent possible, part of the panel system should be assembled before lifting the internal structure frame onto the facility. The remaining panels shall be assembled in two to three sections with appropriate lifting lugs to be used to rapidly lift and aid assembly on the internal steel frame. 7.7. Lifting Fixtures Special lifting fixtures that are used for installation and are required for maintenance shall be designed, documented, fabricated and delivered with the panel system. 8. PAINTING AND CORROSION CONTROL General: Without limiting the general aspects of other requirements of these specifications, all surface preparation, coating and painting of interior and exterior surfaces shall conform to the applicable requirements of the manufacturers printed instructions. The process for surface treatment will be specified by the Contractor, consistent with the recommendations of the paint or process manufacturer, and approved by SOAR. Following approval of a process by SOAR the Contractor will not deviate from the approved process without prior approval by SOAR of the change. For external portions of the Dome, the intent is to provide surfaces that will not corrode, can be easily cleaned, and are cosmetically pleasing. SOAR reserves the right to choose the colors that will be applied from a range of options to be provided by the Contractor. 8.1. Quality Assurance General: Quality assurance procedures and practices shall be utilized to monitor all phases of surface preparation, application and inspection throughout the duration of the project. Procedures or practices not specifically defined herein may be utilized provided they meet recognized and accepted professional standards and are approved by SOAR. Surface Preparation: Surface preparation shall be consistent with the panel Contractors standard process. The process procedure shall be provided to SOAR for approval. Application: No coating or paint shall be applied under the following conditions. When the surrounding air temperature or the temperature of the surface to be coated or painted is (a) below the minimum surface temperature for the products specified herein or (b) too wet or damp less than 2.7C (5F) above the dew point, or (c) when the air temperature is expected to drop below specified minimum temperature within six hours after application of coating. If above conditions are prevalent, coating or painting shall be delayed or postponed until conditions are favorable. The days coating or painting shall be completed in time to permit the film sufficient drying time prior to damage by atmospheric conditions. 8.2. Safety and Health Requirements General: In accordance with requirements set forth by regulatory agencies applicable to the construction industry and manufacturers printed instructions and appropriate technical bulletins and manuals, the Contractor shall provide and require use of personal protective lifesaving equipment for persons working on or about the project site. E-51 DSP99-013

SOAR Dome Specification

8.3. Surface Preparation The removal of all visible oil, grease, dirt, dust, paint, oxides, corrosion products, mold release agents, and other foreign matter by the panel Contractors or paint manufactures standard process. 8.4. Painting Sequence Primer coats shall be applied at the fabrication facility as indicated by the paint manufacturer or Contractors standard procedure. 8.5. Exceptions to Painting Requirements Machined Surfaces: On pieces that contain machined surfaces specifically for mating to other machined or non-machined surfaces, those surfaces are to be left unpainted, and are to be coated with a preservative such as light machine oil and wrapped with a durable waterproof wrapping. All unpainted mating surfaces that are exposed to the air during shipping shall be coated with a removable corrosion inhibitor. Stainless steel shall be left unpainted. The Contractor may request relief from painting other areas of the structure if to do so yields a performance benefit. Such request shall take place during the detailed design. The Contractor may propose alternate standards and processes for painting or other surface finish treatments as appropriate to the materials used and the overall objectives of the SOAR performance and environmental conditions. 8.6. Contamination and Cleaning Surface finish treatments and hardware selected by the Contractor for the Dome shall not generate particles that may contaminate optical surfaces. Finishes shall be compatible with a cleaning process to be defined by the Contractor consistent with the recommendations of the finish supplier.

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APPENDIX F

CONTROLS SYSTEM DESIGN

SOAR Dome Specification

APPENDIX F Dome Control Concept Design

The Dome control system consists of groups of equipment physically located in different areas of the facility. The equipment requires a highly reliable interconnect. For equipment located on the Dome itself, power and individual rough signals may be routed through slip rings. Low level and/or high speed signals shall not be routed through the slip rings. To solve this problem slave controllers on the Dome and shutter are necessary. For this purpose, a spread-spectrum radio modem shall be used to provide communication between the master Dome controller, which will be located in the Control Room, the Dome slave controller, located on the Dome, and the Shutter slave controller, located on the shutter. Figure 1 defines the main elements of the Dome control system. The modem shall be chosen to be compatible with the controller. Recommended equipment and manufacturers are provided in Table 1 at the end of this appendix.

E-stop Dome Drives TCS Encoder Master Dome Controller Vents Interlock Slave Dome Controller Future Data Acquisition I/O (Sensors) Slave Shutter Controller Future Data Acquisition I/O (Sensors) UPS Interlock Shutter Drive Encoder

Manual Control
At the Observing Level

Control Room

Moves with the Shutter

Stationary

Moves with the Dome

Figure 1 Dome Control Block Diagram The master Dome controller, shown in Figure 2, is responsible for directly controlling the position of the Dome through the rotational drives, while the slave shutter controller is responsible for positioning the shutter according to the commands sent by the master Dome controller via the spread spectrum RF modem. The slave Dome controller is primarily intended to serve as a data acquisition unit as well as for interlock and auxiliary I/O (vents). F-54 DSP99-013

SOAR Dome Specification

Spread-Spectrum Radio Modem

RS-232

Network Controller Isolated 4-20mA Outputs Isolated RS-485 Isolated Digital Outputs

TCS

E-stop

Bi-directional Incremental Encoder Absolute Encoder

3 Power

Bi-directional Counter

Barcode Reader G U I Isolated Digital Inputs

4x Dome Drive

Manual Control

Figure 2 Master Dome Controller Diagram 1.0 DOME ROTATIONAL DRIVES AND POSITION SENSORS Four rotational drives with electric motors, helical reduction gearboxes and electromagnetic brakes are used to evenly distribute the rotational drive force. To achieve a highly smooth continuous motion and electromechanical stress free operation, variable speed motor drives must have embedded vectorial torque control capabilities. Due to the nature of the Dome behavior and size, two different position-sensing systems shall be implemented. The first is an absolute encoder in the form of bar code labels or tape fixed underneath the dome ring beam with a simple laser reader and eye protection device. The second sensor is a bi-directional incremental encoder, coupled to the ring beam through a rubber wheel and an articulated arm to ensure a continuous non-slipping contact. The position shall be chosen based on the worst operational case. The main function of this second sensor is to provide information about instantaneous speed and acceleration of the Dome with the high resolution required by the control equipment and implemented algorithms. The alternate function is to provide a means to calculate the Dome position between two markers, thus providing the required positioning accuracy. Since the Dome itself is an extremely inertial control object, slew rate limited control loops (like PIR Proportional Integral Retard) are highly recommended. In this approach, overload of Dome drives and electric power lines will be minimal. Reliable interlock between the application of the brake and rotational state shall also be provided. Reinforced safety procedures shall be adopted to handle overspeed, overcurrent and other exceptional events to avoid damages to the equipment as well as the Dome. This drive control concept is shown in Figure 3. F-55 DSP99-013

SOAR Dome Specification

In order to achieve the required positioning accuracy, a suitable encoder resolution is required. For instance, using barcode labels placed each 10 and a 512 pulses per revolution bi-directional incremental encoder driven by a 250mm outer diameter wheel, provides a resolution better than 0.01. Optionally, a high-resolution (0.05 or better) barcode tape may be used instead of the system described above.

Isolated Digital Outputs

Electromagnetic Brake

Isolated Digital Inputs

E-stop Isolated RS-485 Variable Frequency Drive Electric Motor

3 Power

Encoder Isolated 4-20mA Outputs

Angular Speed

Gearbox

Drive Interface

Figure 3 - Dome / Shutter Drive Diagram. 2.0 DOME AND SHUTTER DRIVE CONTROLLERS Figure 3 defines the Dome and shutter drive control concept design. Each drive controller shall provide all signals necessary to operate the variable frequency drive. In particular an isolated RS485 communication channel for presetting all functional parameters, including overspeed, an isolated 4-20mA output for torque control (Dome rotation) or speed control (shutter opening) and isolated digital inputs and outputs for brake status verification, brake releasing and other necessary interlocks. Adequate level translation devices shall be used in order to guarantee electrical compatibility between the digital I/O and field equipment. Where torque control techniques are used, overspeed protection is essential to avoid damage to the drives. This protection is required in the case of the dome drives.

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SOAR Dome Specification 3.0 SHUTTER DRIVE CONTROL The shutter control system, shown in Figure 4, shall operate in an on/off mode (steps), according to the operational states already described in the control section. Attached to the inner shutter is one rotational drive with an electric motor, helical reduction gearbox and electromagnetic brake. There is only one encoder on the shutter. The same absolute encoder reading device is used for the shutter and for the Dome. A high-resolution (0.05 or better) barcode tape is attached to the underside of the arch girder with the read head attached to the inner shutter door. Reliable interlocks shall be provided, in particular limit switches. A small local uninterruptible power supply (UPS) is required for the slave shutter controller, sensors and radio link. The UPS provides power to these systems during short-term power interruptions. The future component upgrade is for a 10kVA power capacity device such as a heat tape.

Spread-Spectrum Radio Modem

RS-232

Isolated Digital Outputs

Future Component Upgrade

Future Data Acquisition I/O (Sensors)

Isolated Analog Inputs Isolated RS-485 Shutter Drive

Shutter & Windscreen Switches

Isolated Digital Inputs Isolated 4-20mA Outputs Reader Encoder

3 Power

E-stop

M U I

Figure 4 - Slave Shutter Controller Diagram. 4.0 WINDSCREEN COUPLING AND OVERLOAD SWITCH The windscreen is attached to the shutter by mechanical means allowing a rectangular opening for the optical path. To detect abnormal operational conditions, i.e. jamming, an overload switch shall be provided.

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SOAR Dome Specification 5.0 CRANE OPERATION UNIT AND INTERLOCK The Dome control system shall provide a signal to the TCS to confirm the stowed (docked) position of the crane. An interlock shall limit the Dome rotation to 10% of the maximum velocity and accelerations when the crane is not in the stowed position. As an extra safety feature, the crane interlock shall include the hand control unit itself. A wall mount hook or cradle shall be provided to stow the hand unit when not in use. If the hand unit is removed from the hook a switch shall be activated to inform the TCS that the crane is in use and reduced Dome rotation speed is in effect.

Spread-Spectrum Radio Modem

RS-232

Isolated Digital Outputs

Vents

Future Data Acquisition I/O (Sensors)

Isolated Analog Inputs

Isolated 4-20mA Outputs

Auxiliary I/O

3 Power Crane, Damper, Shutter & Windscreen Switches Isolated Digital Inputs M U I E-stop

Figure 5 - Slave Dome Controller Diagram. 3kVA additional power for the auxiliary I/O shall be provided. 6.0 DATA AQUISTION I/O AND VENTS Means to connect future data acquisition I/O sensors shall be provided. Space shall be provided for twenty (20) sensors on each of the Dome and shutter controllers. The sensors and interface cards will be installed by SOAR to provide temperature and humidity data. Both slave controllers shall be able to read and transmit the data to the master Dome controller. The output of the sensors shall be available to the TCS and HVAC control system in degrees Celsius and relative humidity. The Dome slave controller shall control the powered dampers included with the four gravity vents located on the dome for air exchange. In addition, a manually operated switch shall be provided to open the vent dampers.

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SOAR Dome Specification 7.0 MANUAL USER INTERFACE (MUI) The Dome control system shall include manual operation features in order to allow some limited local interactions. 7.1 Hand Paddle The hand paddle consists of a series of buttons with specifically associated functions to rotate the Dome in both directions and to open and close the shutter. These activities are performed at the observing level. SOAR will provide conduits to four different points, next to each Dome drive, to connect the unit. The hand paddle shall include a 15 meter long cable. The cable shall be hardwired into the hand paddle with a connector at the other end. The Contractor shall provide four (4) mating panel type connectors to be mounted in the facility. The implementation of the hand paddle control shall be through an eight-input isolated digital card in the master Dome controller. One input shall serve as a presence status flag to indicate that the unit is in its wall receptacle. A second input shall serve as a readiness status flag to indicate that the unit has been connected to one of the four available connectors. The hand paddle shall have an interlock that sets the status flag that indicates the unit is in use. Only one (1) wall receptacle shall be in use at a time. The remaining six inputs shall be used for the following functions: Rotate Slow Clockwise, Rotate Slow Counterclockwise, Rotate Fast Clockwise, Rotate Fast Counterclockwise, Open the Shutter, Close the Shutter. The slow and fast speed settings shall be adjustable and shall be accessible through the master Dome controller. The master Dome controller shall implement all timing requirements related to the operation of hand paddle. 7.2 Dome MUI Switches shall be provided on the Dome for manual operation of the following subsystems: Individually Open and Close each of the Four Vents, Shutter Emergency Close and Shutter Emergency Open. The last two functions are intended to override the shutter control system. The control system and software shall prevent the operation of these functions when the shutter control system is active. Hardware protection, i.e. activation key, shall be provided.

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SOAR Dome Specification

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Item 1 2

Name

Description

Manufacturer National Instruments Opto22

Part Number Selection Interface cards shall be chosen according to the selected platform. SNAP series with 16-slot backplane and 120V power supply. Brain and I/O modules as needed to support the specified field devices. SNAP series with 16-slot backplane and 120V power supply. Brain and I/O modules as needed to support the specified field devices. G5 series according to the power of the motor. According to M3 specification.

Internet Site www.natinst.com www.opto22.com

Master Dome PCI or CompactPCI Controller based controller for the Dome. Slave Dome Controller placed in Controler the Dome for remote actuation.

Slave Shutter Controller

Controller placed in the shutter for remote actuation.

Opto22

www.opto22.com

4 5 6 7 8 9 10 11

Dome / Shutter Variable frequency Drive drive for the motors. Dome / Shutter Electric motor. Drive Dome Encoder Barcode labels. Dome Encoder Barcode reader. Dome Encoder Bidirectional incremental encoder.

EMS SEW Planner Keyence

www.emsdrives.com www.seweurodrive.com

SOAR Dome Specification

Table 1. Control System Recommended Equipment

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