Slide 1

Indus Controls Overview

Pravin Fatnani
([email protected])
Accelerator Controls
RF Systems & Controls Division
Raja Ramanna Centre For Advanced Technology
(RRCAT), Indore
EPICS 2009, RRCAT
January 28, 2009


Slide 2

Indus Accel. Complex: Schematic

INDUS-2

TL-3

EPICS 2009, RRCAT
January 28, 2009


Slide 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

EPICS 2009, RRCAT
January 28, 2009


Slide 4

Accuracy and Stability of References to PS
for Indus-2

S.No

Reference for (Power Supply
type)

Accuracy & Stability
Desired
(Requirement)
At Full scale

Accuracy & Stability
Available (Provided)
At Full scale

1

Dipole Magnet P/Ss –I2

50 ppm

15 ppm ( 0.0015% )

2.

Quadrupole Magnet P/Ss–I2
50 ppm
(Q1,Q2,Q3,Q4,Q5 types)

15 ppm ( 0.0015% )

3.

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

60 ppm ( 0.0060% )

1000 ppm

EPICS 2009, RRCAT
January
28, 2009
500 ppm


Slide 5

INDUS-2 CONTROLS - Scheme & Data Flow
WORK
STATION # 1

WORK
STATION # 2

(Pentium)

(Pentium)

USER INTERFACE
LAYER

WORK
STATION # N
(Pentium)

ETHERNET
SC FOR VACUUM

SC FOR MAG P/S
C

E

P

E

R

T

R

T

U

O

H

U

O

H

F

E

I

R

6

F

E

6

8

I

R

8

N

0

E

4

4
0

#1

R

8
5

P
R
O
F
I
B
U
S

P
R
O
F
I

C
P
U
6
8
K

0

T

EC #1

S
4

L
A
Y
E
R

P

P

P

0

E
C

SC LAYER

C

P/S #1

I
O
B
O
A
R
D

P/S #2

S
4
8

P
R
O
F
I

C
P
U

5

6
8
K

I

I
O
B
O
A
R
D

O
B
O
A
R
D

P
R
O
F

5

P/S
#10
P/S
#16

EIU
#31

R

S
4
8
5

C
P
U
6
8
K

P
R
O
F
I

I
O
B
O
A
R
D

P/S #P
I
O
B
O
A
R
D

P/S
#Q

PUMPS

I
B
U
S

P/S #R
EPICS
Indus
Control2009,
SystemRRCAT
Essentials
January 28, 2009

GATE VALVES

E
T

EIU #1

S

P/S #8

P/S #9

R

R#1

8

EIU #2

GAUGES

N

4

I
O
B
O
A
R
D

VACUUM

P
R
O
F
I

C
P
U
6
8
K

P #1

I

I
O
B
O
A
R
D

O
B
O
A
R
D

P #2

G #8

EIU #2
P #9

R
S
4
8

P
R
O
F
I

C
P
U
6
8
K

I

I
O
B
O
A
R
D

O
B
O
A
R
D

5

P #10

G #16

EIU
#31

R
S

C
P
U

4
8
5

6
8
K

P
R
O
F
I

I
O
B
O
A
R
D

P #I
I
O
B
O
A
R
D

G #J

V #K

5


Slide 6

SCHEME OF INDUS-2 CONTROL SYSTEM

WORK
STATION # 1
(Pentium)

USER INTERFACE
LAYER

WORK
STATION # 2
(Pentium)

WORK
STATION # N
(Pentium)

ETHERNET
SC FOR VACUUM

SC FOR MAG P/S
C
P
U
6
8
0
4
0

P
R
O
F
I

P
R
O
F
I

P
R
O
F
I

#1

#2

#3

E
T
H
E
R
N
E
T

C
P
U
6
8
0
4
0

SC LAYER

R
S
4
8
5

P
R
O
F
I

P
R
O
F
I

P
R
O
F
I

#1

#2

#3

E
T
H
E
R
N
E
T

PROFI BUS
Telegrams

EC #N

EC #1

E
C
L
A
Y
E
R

P/S #P

P/S #1
C
P
U
6
8
K

P
R
O
F
I

I
O
B
O
A
R
D

I
O
B
O
A
R
D

P/S #2

C
P
U

P/S #8

6
8
K

EC #2

P
R
O
F
I

I
O
B
O
A
R
D

P/S #9
C
P
U

RS485

6
8
K

P
R
O
F
I

I
O
B
O
A
R
D

I
O
B
O
A
R
D

P/S
#10
P/S

EPICS 2009, RRCAT#16
January 28, 2009

R
S
4
8
5

I
O
B
O
A
R
D

P/S #Q

P/S #R


Slide 7

Software Architecture for Indus-2 Control System
Database

Intranet

Web
Clients

C++

Labview

PVSS-2
SCADA

Matlab

Java

UI

Data Acquit ion
and operator interface
software

Java
Application

C++
Application

TCP/IP

Machine
Application
Programs

MOD
Bus

LPC, DSO, DMM, FG, RGA

Custom
Protocol

Communication
Protocols

Front-end
Instruments/Equipments

EPICS 2009, RRCAT
January 28, 2009


Slide 8

Software at Layer-1
PVSS SYSTEM

DM

Operator
Console
PVSS UI

EV
API

API

Operator
Console
PVSS UI

API

Data

Data to/from local controller

EPICS 2009, RRCAT
January 28, 2009

Ethernet


Slide 9

Software at Layer-2
•PROFIBUS master protocol is
implemented on Motorola 68040
based MVME-162 CPU Board with
OS-9

TCP/IP Network
68040 CPU Board

• It performs various Profibus
Services like:

Socket Process

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

Profi
Master
Board

SOS

Profi-Master
Aux
Process1

Optional Mgmt.
Board 1

• TCP/IP datagram socket server
running at Layer-2 communicates
with GUI program at Layer-1.
EPICS 2009, RRCAT
January 28, 2009

Aux.
Process2

Optional Mgmt.
Board 2

P
R
O
F
I
B
U
S


Slide 10

Software at Layer-3
PROFIBUS Slave protocol has been
implemented on in-house developed
Motorola 68000 based CPU boards.

68000 CPU Board

Real Time Operating System OS-9
customized and ported.

Profi
Slave

P
R
O
F
I
B
U
S

Profi
Slave
Board

It performs functions like:
•Collecting Data from and setting
data to various I/O cards

I/O
Proc 1

I/O
Proc 2

I/O
Proc 3

I/O
Proc 4

•Receiving and parsing Profi
telegrams from master.
•Passing the data to master when
asked.
•Maintaining slave configuration,
SAP list etc

Analog I/P
Digital O/P
Digital I/P
Analog O/P
Board (Relay) Board(Opto) Board (DAC) Board(ADC)

EPICS 2009, RRCAT
January 28, 2009

P
R
O
F
I
B
U
S


Slide 11

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 12

ProfiBus Developments
• DP Master & Slave boards
• Master-Slave communication only
• Baud rate 750K

EPICS 2009, RRCAT
January 28, 2009


Slide 13

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.


EPICS 2009, RRCAT
January 28, 2009


Slide 14

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.

EPICS 2009, RRCAT
January 28, 2009


Slide 15

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
C
O

• FLASH : 1 MB

N

• Two RS-232 serial ports

T

• On Board Ethernet Controller

R
O

• OS-9 BSP installed

L

• On board RTC

S

• Program Downloading during testing : Serial / Ethernet

These are the readymade boards purchased from Motorola.
Model : MVME-162

EPICS 2009, RRCAT
January 28, 2009


Slide 16

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 17

An Overview of
PVSS SCADA

EPICS 2009, RRCAT
January 28, 2009


Slide 18

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
EPICS 2009, RRCAT
January 28, 2009


Slide 19

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
EPICS 2009, RRCAT
January 28, 2009


Slide 20

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
EPICS 2009, RRCAT
January 28, 2009


Slide 21

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 22

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 23

PVSS Managers
• A PVSS application is composed of several
processes, in PVSS nomenclature: Managers.
• These Managers communicate via a PVSSspecific 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.
EPICS 2009, RRCAT
January 28, 2009


Slide 24

Managers Overview

EPICS 2009, RRCAT
January 28, 2009


Slide 25

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
EPICS 2009, RRCAT
January 28, 2009

EV

DM


Slide 26

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
EPICS 2009, RRCAT
January 28, 2009


Slide 27

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 28

PVSS API & GUI
for Indus-2 Control System

EPICS 2009, RRCAT
January 28, 2009


Slide 29

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 30

PVSS structure
• User Interface
layer
• Processing
Layer
• Communication
& Memory layer
• Driver Layer
EPICS 2009, RRCAT
January 28, 2009


Slide 31

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.

EPICS 2009, RRCAT
January 28, 2009


Slide 32

API Manager in Indus-2 Control System
PVSS Server
UI

UI
DB

EV
Panel

API

SC layer ( L2)
VME

SC layer ( L2)
VME

EPICS 2009, RRCAT
January 28, 2009


Slide 33

Number of Parameters Handled
System Name

No of Signals (approx)

MPS

4200
1600
400
100
500
300
300
250
200
~8000

Vacuum
RF
Timing
BDS
RSSS
BLFE
Interlock

Orbit Correction

Total
EPICS 2009, RRCAT
January 28, 2009


Slide 34

Few screenshots (MPS)

EPICS 2009, RRCAT
January 28, 2009


Slide 35

RF

EPICS 2009, RRCAT
January 28, 2009


Slide 36

BLFE

EPICS 2009, RRCAT
January 28, 2009


Slide 37

Vacuum

EPICS 2009, RRCAT
January 28, 2009


Slide 38

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
EPICS 2009, RRCAT
January 28, 2009


Slide 39

INDUS-2 LCW Plant Control Software Architecture
Ethernet

RS-485

VME service

RS-485 service

Com. service
PVSS data publish service

Data log service

Global data table

GUI service

Debug service

Control service

Event service

Module for Redundancy

Access control and
maintenance/repair
management service

Configuration Files for defining system state

EPICS 2009, RRCAT
January 28, 2009

Help service
Configuration data table
generation service


Slide 40

Indus 2 RGA system main GUI Panel

EPICS 2009, RRCAT
January 28, 2009


Slide 41

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.

EPICS 2009, RRCAT
January 28, 2009


Slide 42

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.

EPICS 2009, RRCAT
January 28, 2009


Slide 43

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
C
O
N
T
R
O

 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

L
S

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

EPICS 2009, RRCAT
January 28, 2009


Slide 44

EPICS 2009, RRCAT
January 28, 2009


Slide 45

Web Based Applications
•
•
•
•

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

EPICS 2009, RRCAT
January 28, 2009


Slide 46

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.

EPICS 2009, RRCAT
January 28, 2009


Slide 47

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)

EPICS 2009, RRCAT
January 28, 2009


Slide 48

Screenshot: Indus OnLine (Synoptic Display)

EPICS 2009, RRCAT
January 28, 2009


Slide 49

Screenshot: Indus OnLine (Data Query Form)

EPICS 2009, RRCAT
January 28, 2009


Slide 50

Screenshot: Indus OnLine (Data Query Result)

EPICS 2009, RRCAT
January 28, 2009


Slide 51

Screenshot: Indus OnLine (Data Query Form)

EPICS 2009, RRCAT
January 28, 2009


Slide 52

Screenshot: Indus OnLine (Data Query Result)

EPICS 2009, RRCAT
January 28, 2009


Slide 53

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

EPICS 2009, RRCAT
January 28, 2009


Slide 54

Screenshot: Indus Machine Status Display

EPICS 2009, RRCAT
January 28, 2009


Slide 55

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

EPICS 2009, RRCAT
January 28, 2009


Slide 56

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 57

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 58

Screenshot: FIS (Fault Logger)

EPICS 2009, RRCAT
January 28, 2009


Slide 59

Screenshot: FIS (Fault Acknowledger)

EPICS 2009, RRCAT
January 28, 2009


Slide 60

Screenshot: FIS (Fault Explorer Query Result)

EPICS 2009, RRCAT
January 28, 2009


Slide 61

Screenshot: FIS (Fault Analyzer)

EPICS 2009, RRCAT
January 28, 2009


Slide 62

CPU-1
• 68K CPU running at
8 MHz.
• On board 16 KB RAM &
16 KB EPROM.
• On board assembler, disassembler and debugger.
• 1 serial port RS 232 .
• 1 parallel port.
• On board bus arbitration.
• Seven interrupt levels.

EPICS 2009, RRCAT
January 28, 2009


Slide 63

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 64

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.
EPICS 2009, RRCAT
January 28, 2009


Slide 65

RELAY OUTPUT BOARD
• 32 relay contact
outputs, isolated and
potential free.
• O/P status indication.
• Address selection
through DIP
switches.

EPICS 2009, RRCAT
January 28, 2009


Slide 66

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
through DIP switches.

EPICS 2009, RRCAT
January 28, 2009


Slide 67

2 CHANNEL DELAY GENERATOR
• Input is optically isolated.
• 2 independent
programmable delay
outputs.
• Coarse delay up to 6 msec
resolution : 0.1 msec.
• 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.

EPICS 2009, RRCAT
January 28, 2009


Slide 68

4 CHANNEL DELAY GENERATOR
• Input is optically isolated.
• 4 independent delayed o/ps.
• Programmable Coarse
delay up to 6 msec.
resolution : 0.1 msec.
• Selectable clock rate.
• Output : 50 ohm drive
capacity.
• Address selection through
DIP switches.

EPICS 2009, RRCAT
January 28, 2009


Slide 69

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.

EPICS 2009, RRCAT
January 28, 2009


Slide 70

BIPOLAR DAC BOARD
• 8 Analog bipolar
outputs.
• 16 bit resolution.
• Simultaneous update
of all outputs.
• On board DC-DC
converter.
• Address selection
through DIP switches.

EPICS 2009, RRCAT
January 28, 2009


Slide 71

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
through DIP switches.
EPICS 2009, RRCAT
January 28, 2009


Slide 72

Thank
You.
EPICS 2009, RRCAT
January 28, 2009