EPICS 2009, RRCAT January 28, 2009 Indus Controls Overview Pravin Fatnani ([email protected]) Accelerator Controls RF Systems & Controls Division Raja

EPICS 2009, RRCAT January 28, 2009

Indus Controls Overview

Pravin Fatnani([email protected])Accelerator Controls

RF Systems & Controls DivisionRaja Ramanna Centre For Advanced Technology

(RRCAT), Indore


Indus Accel. Complex: Schematic

INDUS-2

TL-3


Major Parameters

• Microtron 20 MeV• Booster – 450/ 650 MeV• Indus-1 – 450 MeV, 100 mA• 2.5 GeV, 300 mA (2.5 GeV, 50 mA reached)• Energy ramping from 600 MeV to 2.5 GeV with

varying slopes – fastest ~ 130Hz


Accuracy and Stability of References to PS for Indus-2

S.NoReference for (Power Supply

type)

Accuracy & Stability Desired

(Requirement)

Accuracy & Stability Available (Provided)

At Full scale At Full scale

1 Dipole Magnet P/Ss –I2 50 ppm 15 ppm ( 0.0015% )

2.Quadrupole Magnet P/Ss–I2

(Q1,Q2,Q3,Q4,Q5 types)50 ppm 15 ppm ( 0.0015% )

3.Sextupole Magnet P/Ss –I2(S1,S2,Sh, types)

1000 ppm 60 ppm ( 0.0060% )

4. Steering Magnets500 ppm

60 ppm ( 0.0060% )

5. All other Magnets of I2 and TL3 500 ppm 60 ppm ( 0.0060% )


EC

LAYER

USER INTERFACE LAYER

SC LAYER

R

S

4

8

5

P/S #2

ETHERNET

SC FOR VACUUM

P/S #8

P/S #1

C

P

U

6

8

0

4

0

P

R

O

F

I

#1

E

T

H

E

R

N

E

T

CPU

68K

PROFI

I

OBOARD

IOBOARD

P/S #Q

P/S #P

P/S #R

P/S #10

P/S #9

P/S #16

R

S

4

8

5

R

S

4

8

5

EIU #31

EC #1

EIU #2

SC FOR MAG P/S

WORK STATION # 2

(Pentium)

WORK STATION # 1

(Pentium)

P #2

G #8

P #1

G #J

P #I

V #K

P #10

P #9

G #16

VACUUMGAUGES

PUMPS

GATE VALVES

WORK STATION # N

(Pentium)

C

P

U

6

8

0

4

0

P

R

O

F

I

#1

E

T

H

E

R

N

E

T

CPU

68K

PROFI

I

OBOARD

IOBOARD

CPU

68K

PROFI

I

OBOARD

IOBOARD

PROF

I BUS

R

S

4

8

5

CPU

68K

PROFI

I

OBOARD

IOBOARD

R

S

4

8

5

R

S

4

8

5

EIU #31

EIU #1

EIU #2

CPU

68K

PROFI

I

OBOARD

IOBOARD

CPU

68K

PROFI

I

OBOARD

IOBOARD

PROF

I BUS

INDUS-2 CONTROLS - Scheme & Data Flow

5Indus Control System Essentials


SC LAYER

EC

LAYER

USER INTERFACE LAYER

RS485

P/S #2

ETHERNET

SC FOR VACUUM

P/S #8

P/S #1

CPU68040

PROFI

#1

PROFI

#2

ETHERNET

PROFI

#3

CPU 68K

PROFI

IOBOARD

IOBOARD

P/S #Q

P/S #P

P/S #R

P/S #10

P/S #9

P/S #16

R S 4 8 5

RS485

EC #N

EC #1

EC #2

SC FOR MAG P/S

WORK STATION # 2

(Pentium)

WORK STATION # 1

(Pentium)

WORK STATION # N

(Pentium)

CPU68040

PROFI

#1

PROFI

#2

ETHERNET

PROFI

#3

CPU 68K

PROFI

IOBOARD

IOBOARD

CPU 68K

PROFI

IOBOARD

IOBOARD

PROFI BUSTelegrams

SCHEME OF INDUS-2 CONTROL SYSTEM


Software Architecture for Indus-2 Control System

MOD Bus

Custom Protocol

TCP/IP

LPC, DSO, DMM, FG, RGA

Labview

C++ Application

Java Application

PVSS-2 SCADA

JavaMatlabC++

Database

Web Clients

UI

Communication Protocols

Machine Application Programs

Front-end Instruments/Equipments

Data Acquit ion and operator -interface software

Intranet


Software at Layer-1

Operator Console

PVSS UI

Operator Console

PVSS UIEV

API APIAPI

DM

PVSS SYSTEM

Data to/from local controllerData

Ethernet


PROFIBUS

TCP/IP Network

SOS

Profi-Master

AuxProcess1

Aux.Process2

ProfiMasterBoard

Optional Mgmt. Board 1

Optional Mgmt. Board 2

Socket Process

68040 CPU Board

Software at Layer-2

•PROFIBUS master protocol is implemented on Motorola 68040 based MVME-162 CPU Board with OS-9

• It performs various Profibus Services like:

Parameterize and Configuring Slaves, Maintaining list of live slaves,periodic data collection from slaves, maintaining Master’s configuration etc.

• TCP/IP datagram socket server running at Layer-2 communicates with GUI program at Layer-1.


PROFIBUSProfi

Slave

I/OProc 1

I/OProc 2

I/OProc 3

I/OProc 4

ProfiSlaveBoard

Digital O/PBoard (Relay)

Digital I/PBoard(Opto)

Analog O/PBoard (DAC)

Analog I/PBoard(ADC)

PROFIBUS

68000 CPU Board

Software at Layer-3

PROFIBUS Slave protocol has been implemented on in-house developed Motorola 68000 based CPU boards.

Real Time Operating System OS-9 customized and ported.

It performs functions like:

•Collecting Data from and setting data to various I/O cards

•Receiving and parsing Profi telegrams from master.

•Passing the data to master when asked.

•Maintaining slave configuration, SAP list etc


OS9 Developments

• Device drivers for more than 20 types of VME based I/O boards.

• Device descriptor development for these boards.

• Layer-2 software for 8 stations of different sub-systems

• Layer-3 software for more than 75 stations.


ProfiBus Developments

• DP Master & Slave boards

• Master-Slave communication only

• Baud rate 750K


Features of Profi Board

High speed 8-bit Micro controller Dallas 80C420 operating at 24

MHz 16KB EPROM for firmware and 16 KB SRAM for Data Storage. 16KB Shared-RAM, shared by Profi bus controller and VME Bus. Provides two asynchronous serial ports, one supporting

communication over RS 232C

and baud rate programmable from 1.2K to 19.2K. Other port is user

selectable either RS

232C or RS 485 (2 wire or 4 wire) and supports baud rates from

9.6K to 750K. Capable of interrupting VME master at levels (1,2,4,5), which is

Jumper selectable,

configurable vector number through DIP switches. Can be interrupted by VME master. 1K bit Serial EEPROM for Parameter storage.


Hardware Developments

• > 20 types of VME boards developed and used for Indus-2 controls

• CPU, ADC, DAC, Opto-in, Relay, Ramp controller, Clock generator, Timing delay generator, Coincidence generator, C-V converters etc.


CPU Boards at Layer-2

Some of the features of the CPU boards used at Layer-2 :

• VME-32 compliant

• Motorola 68040 CPU running @ 32 MHz

• RAM : 4 MB

• FLASH : 1 MB

• Two RS-232 serial ports

• On Board Ethernet Controller

• OS-9 BSP installed

• On board RTC

• Program Downloading during testing : Serial / Ethernet

These are the readymade boards purchased from Motorola.

Model : MVME-162

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CPU Boards at Layer-3

Some of the features of the CPU boards used at Layer-3 :

• VME-16 compliant

• Motorola 68000 CPU running @ 8 MHz

• RAM : 1 MB

• EPROM : 1 MB

• Two RS-232 serial ports

• OS-9 customized and ported

• Program Downloading during testing : Serial

These CPU boards have been Developed In-House by Controls Group.


An Overview ofPVSS SCADA


Functions performed by Layer-1

• Get the device data (status & values) from layer-2, process it and make available for display on operator console.

• Send the control/set command from the operator console to layer-2.

• Log the device data • Log the errors & events• Generate alarms and display• Display of history data


PVSS-II

• The SCADA chosen for Indus-2 control system is PVSS from an Austrian company ETM.

• PVSS, the process visualization and control system of ETM


PVSS II

• PVSS introduction & Managers• Data Point Concept• GUI & Scripting• Alarm concept• Archiving, Trending & other features• Distributed and Redundant systems• Managing PVSS projects• Interface to External Applications


Introduction

• PVSS II is a SCADA system. • SCADA stands for Supervisory Control

And Data Acquisition.• PVSS is used to connect to hardware (or

software) devices, acquire the data they produce and use it for their supervision, i.e. to monitor their behaviour and to initialize, configure and operate them.


General features of a SCADA

• Tag /Data Point mapping of the Process parameter.

• Interface to Hardware• Alarms, Trends, HMI.• DB logging, Event logging, Archiving.• Access control, Multi-user development,

interface to external Applications, Backup.• Independent, reliable, flexible, expandable.• PVSS supports all the above features.


PVSS Managers

• A PVSS application is composed of several processes, in PVSS nomenclature: Managers.

• These Managers communicate via a PVSS-specific protocol over TCP/IP.

• Main managers are – Event Manager (EV)– Database Manager (DB).

• Managers subscribe to data and this is then only sent on change by the Event Manager, which is the heart of the system.


Managers Overview


Manager Functions

• Event manager – responsible for all

communications.– It receives data from various

managers and sends it to the Database Manager to be stored in the data base

– distributes data to all Managers

• Database manager – provides the interface to the (run-

time) data base. – Administration of system

parameterization

EVEV

DMDM


PVSS Managers Contd..

• User Interface Manager (UI) (Two Modes)– Editor : Parameterization and HMI design.– Visualization: Run time HMI

• API Manager – Allow users to write their own programs in C++ using a

PVSS API (Application Programming Interface) to access the data in the PVSS database & interface external applications.

• Control Manager (CTRL)– provide for any data processing as “background”

processes


PVSS Managers Contd..

• Driver Manager (DRV)– Provide the interface to the devices to be controlled.

These can be PVSS provided drivers like Profibus, OPC, etc.

• ASCII Manager (ASCII)– Allows users to export/import the configuration of a

project (DPTs/DPs – see later) to/from an ASCII file.

• Archive Manager– Allows users to archive data for later retrieval and

viewing.


PVSS API & GUIfor Indus-2 Control System


What is an API manager?• The Application Program Interface provided

by PVSS for the integration of external programs.

• Allow users to write their own programs in C++ using PVSS APIs to access the data in the database and to interact with external applications.

• It communicates with the PVSS system via a protocol defined by PVSS.


PVSS structure

• User Interface layer

• Processing Layer

• Communication & Memory layer

• Driver Layer


APIs in Indus Control system

• Used to connect PVSS SCADA to Layer-2 of control System.

• API manager communicates with L-2 on TCP/IP link.


API Manager in Indus-2 Control System

SC layer ( L2)VME

SC layer ( L2)VME

PVSS Server

API

DB EVUI

PanelPanel

UI


Number of Parameters HandledSystem Name No of Signals (approx)

MPS 4200Vacuum 1600

RF 400Timing 100BDS 500

RSSS 300BLFE 300

Interlock 250Orbit Correction

Total200

~8000


Few screenshots (MPS)


RF


BLFE


Vacuum


LabVIEW Developments

• Indus-2 LCW plant and field SCADA system (PANI)

• ~700 parameters

• Concept of Services

• Indus-2 RGA Interface Software

• Indus-2 Ring Temperature Monitoring and Vac Chamber Safety System


INDUS-2 LCW Plant Control Software Architecture Ethernet

RS-485

VME service RS-485 service Com. service

Data log service Global data table

Debug service Control service

GUI service

Event service

Configuration Files for defining system state

Help service Access control and maintenance/repair management service

Module for Redundancy

PVSS data publish service

Configuration data table generation service


Indus 2 RGA system main GUI Panel


FEATURES OF L1-L2 COMMUNICATION

1. The L1-L2 communication uses TCP/IP datagram sockets.

2. TCP/IP protocol uses its own error detection mechanisms.

3. L1-L2 communication sockets form one-to-one dedicated connections, thus avoiding problems of multicast or broadcast.

4. Every command is followed by a response that reflects the result of the service.


FEATURES OF L2-L3 COMMUNICATION

1. Galvanic Isolation has been provided on Profibus at all the stations.

2. Parity check on byte level for Profibus telegrams (packets). Every byte of the profi telegram has even parity included.

3. Frame checksum at packet level has been provided. Each profi telegram consists of a checksum byte that helps in checking the data integrity.

4. Multiple attempts: Provision for up to 3 attempts has been included at L-2 for each command that is sent to L-3 in case of no- reply /frame-error.


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Diagnostics Information Available

L-3 station status at L-2 and L-1 ( A / S / F / U )

Bus-error status of L-3 cards at L-1

Board temperature info for L-3 I/O boards at L-1 (in MPS system )

L-3 CPU running state at L-2 and L-3.

L1-L2 communication status at GUI

API running status at GUI

DAC readback by ADC for end-to end confirmation (in MPS system )



Web Based Applications

• Online Machine Status Display System

• Machine History Data Query

• Fault Information System

• E-Log-Book


Web Applications

• Online Machine Status Display System• Machine History Data Query• Fault Information System• E-Log-Book

No web application is being used for controlling the Indus-1 or Indus-2 machines.


Indus OnLine

Objective: This web site provides Indus experimental data to RRCAT Intra Net Users.

URL:http://srs.cat.ernet.in

Data Display:Live (Text/Synoptical), Historical (tabular/Graphical)

Data Query Method:User Friendly Web Pages (Query Forms)

http://srs.cat.ernet.in/

http://srs.cat.ernet.in/


Screenshot: Indus OnLine (Synoptic Display)


Screenshot: Indus OnLine (Data Query Form)


Screenshot: Indus OnLine (Data Query Result)


Screenshot: Indus OnLine (Data Query Form)


Screenshot: Indus OnLine (Data Query Result)


Machine Status Display System

Objective: This web application provides Indus Storage Ring Status Display on the large size monitors placed at different places of Indus complex.

URL:http://srs.cat.ernet.in/machinestatus.htm

Data Display:Text, graph

http://srs.cat.ernet.in/machinestatus.htm



Screenshot: Indus Machine Status Display


Fault Information System (FIS)

Objective: This web application is designated to track the faults encountered in various Indus sub systems involved in operations of Indus-1 & Indus-2.

URL:http://srs.cat.ernet.in/fis.htm

Data Display:Tabular, graphical




FIS Functions:

Fault Logger: Logs new faults.

Fault Acknowledger:Acknowledges the logged faults.

Fault Explorer:Explorers the logged historical faults.

Fault Analyzer:Displays the Statistics of logged historical faults.

Expert Info Viewer:Displays the device names & its concerned persons.


FIS Functions: cont….

Shift Summary Logger: Logs Shift (Experiment) Summary.

Shift Summary Viewer:Displays the Queried Shift (Experiment) Summaries.

System Modification/Updation Logger:Logs the Indus Sub Systems’ Modifications/Updation Information.

System Modification/Updation Viewer:Displays the Queried Sub Systems’ Modification/Updation Information.


Screenshot: FIS (Fault Logger)


Screenshot: FIS (Fault Acknowledger)


Screenshot: FIS (Fault Explorer Query Result)


Screenshot: FIS (Fault Analyzer)


CPU-1

• 68K CPU running at 8 MHz.

• On board 16 KB RAM & 16 KB EPROM.

• On board assembler, dis-assembler and debugger.

• 1 serial port RS 232 .• 1 parallel port.• On board bus arbitration. • Seven interrupt levels.


CPU-2 with OS9• CPU 68K running at

8/16 MHz.• 128KB firmware.• 256/512KB SRAM.• Additional EPROM

256KB/512KB/1MB.• Two Serial ports

RS 232 and RS 485.• 16 Bit Timer.• Single level Bus

arbitration.• 7 levels of interrupts.


DIGITAL INPUT BOARD• 32 Optically isolated

inputs.• I/P latching @ 8 MHz.• Address selection

through DIP switches.• Channels can be

configured to interrupt VME CPU.


RELAY OUTPUT BOARD• 32 relay contact

outputs, isolated and potential free.

• O/P status indication.• Address selection

through DIP switches.


12 BIT ADC BOARD

• 16 differential / 32 single ended analog inputs.

• 12 bit resolution.• Free running mode of

operation.• Look-up table for

linearisation of I/P.• Address selection



2 CHANNEL DELAY GENERATOR

• Input is optically isolated.• 2 independent programmable

delay outputs.• Coarse delay up to 6 msec

resolution : 0.1 sec.• Fine delay up to 250 nano sec

resolution : 1 nano sec.• Fine delay can be up to 10 pico

sec. • Output : 50 ohm drive capacity.• Address selection through DIP

switches.


4 CHANNEL DELAY GENERATOR

• Input is optically isolated. • 4 independent delayed o/ps.• Programmable Coarse

delay up to 6 msec. resolution : 0.1 sec.• Selectable clock rate. • Output : 50 ohm drive

capacity.• Address selection through

DIP switches.


FIELD BUS CONTROLLER• Intelligent controller for

field bus implementation.• 16 KB shared RAM.• 16 KB SRAM. • 16 KB firmware.• 2 serial ports: RS 232 &

RS 485.• Capable of interrupting

VME master.• Address selection through

DIP switches.


BIPOLAR DAC BOARD

• 8 Analog bipolar outputs.

• 16 bit resolution.• Simultaneous update

of all outputs.• On board DC-DC

converter.• Address selection



8 CHANNEL DAC BOARD• 8 Analog unipolar

outputs.• Voltage / current outputs. • 16 bit resolution.• 4 channel opto-coupled

outputs.• On line output trimming

facility.• Read back of set value.• Address selection



ThankYou.

Documents

EPICS 2009, RRCAT January 28, 2009 Indus Controls Overview Pravin Fatnani ([email protected]) Accelerator Controls RF Systems & Controls Division Raja