1. Control System Pravin Fatnani Accelerator Control Section IIFC Meeting RRCAT Presentation 24-25 Feb 2015

2. Control System Developments Control system for 20 MeV Microtron & Transport Line-1 Control system for 450 MeV Booster & Transport Line-2 Control system for Indus-1, 450 MeV SRS Control system for Indus-2, 2.5 GeV SRS Control system for Vertical Test Sand (VTS) Control system for Agricultural Radiation Processing Facility (ARPF) Control system for 10 MeV Linac at RRCAT Control system for H- ion source IIFC Meeting RRCAT Presentation 24-25 Feb 2015 2

3. Control System: 20 MeV Microtron VME based control system No. of parameters ~150 (isolated) Unified control system catering to all subsystems of the pre-injector Control software in VME CPU 68000 developed in assembly, C etc. GUI and server programs in EPICS Cycling and degaussing for all the magnets Machine safety interlocks Generates master trigger for all the accelerators in Indus complex 3 EPICS OPI for Microtron Microtron Operator Console

4. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 Control System: 450 MeV Booster MPS and RF track dipole power supply reference Optical fiber for timing triggers Control Software in OS-9 and assembly of MC 68000 Client and server programs in Visual C/ LabVIEW/ PVSS VME based control system No. of parameters ~750 (Vac, RF, MPS, RMS, Timing) Programmable current & voltage reference to all power supplies Typical accuracy of references - 100 ppm 4 VME Equipment Control Station Daisy Chained MPS Control Modules

5. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 Control System: Indus-1 (450 MeV SRS) Parameters ~900 (Vac, RF, MPS, RMS, Timing) MPS reference stability better than 100 ppm Simultaneous cycling of all magnets Coarse and fine delay adjustments for beam injection (< 5 ns) Parameter save, restore, logging & retrieval and alarms 5 Upgradation New intelligent equipment control modules for MPS control upgradation

6. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 3- layer architecture No. of parameters: 10,000 + Technical sub-systems: MPS, Timing and PPS, RF, Vac, Beam Diagnostics, Radiation Monitoring, IDs, BLFE, LCW and Pneumatic systems Hardware: Mostly VME based, in-house developed. Machine control applications: Magnet cycling, bunch filling, injection, ramping, orbit bumps, orbit feedbacks, tune feedback, diag BLs, ID control Control System: Indus-2 (2.5 GeV SRS) 6 VME equipment controller Equipment control stations Control system scheme

7. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 Layer-1 : PVSS (SCADA) Servers, PVSS GUI Clients, Database Servers, Domain Controller, Gateway, Firewall, Web Servers etc. in server room and control room Layer-2 : One VME Station ( Profibus master) for each sub-system. Total 9 stations. Each VME station has: –Motorola MVME-162 CPU Board with RTOS OS-9 –In-house developed Profibus Board. Communication Links: TCP/IP for Layer-1 and ProfiBus for Layer-3 Layer-3 : Several VME Stations (Profibus slaves) for each sub-system. Total ~ 90 stations. Each VME station has in-house developed : –Motorola 68000 CPU board with RTOS OS-9 –Profibus boards –Various Analog & Digital IO Boards. Total boards 1200+ Communication Links: ProfiBus for Layer-2 Indus-2 Control System.... 7

8. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 Indus-2 Control System Highlights Inhouse developed VME boards (25 types) and control modules Extensive Data-logging of all parameters. User action logging. Various Diagnostic information for each layer. Machine Safety and Interlock System. Alarm Handling System. Web based Services on intranet Isolated switched network along with strong security features Computing & Network Infrastructure with managed switches and UPS power back-up Global slow and fast orbit feedback systems with automatic system response identification and controller tuning features. 8

9. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 9 System Diagnostics Layer-3 station status Bus-error status of Layer-3 boards Layer-1 & Layer-2 communication status API running status Parameter deviation alarms Alarms on system parameters. Error and information logs at various levels in PVSS DAC readback by ADC for end-to end confirmation Board temperature info for I/O boards Web based Data Diagnostics L3 Stn & API Status Panel Alarm Panel

10. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 10 Web Based Services Live machine Status Historical Data retrieval Electronic Logbook (eLogbook) Fault Logbook (FLogbook) Beamline Booking Management Machine Shutdown Management Standing Instructions Management Work Plan Management e-Noticeboard Information Display

11. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 Timing System for Indus-1 & 2 Booster RF: 31.613 MHz for I-1 timing Indus-2 RF: 505.8 MHz for I-2 timing Coincidence generation with fast digital electronics for proper extraction and bucket filling Jitter in trigger signals < 2 n sec Support for 3 filling modes : Single, 3 symmetric and Multi bucket Fibre optic interface for noise suppression and isolation Synchronized injection hold Interlocked Indus-1/ Indus-2 injection mode Equipment Controller for I-2 Timing Control System Coincidence Generator for I-2 Timing Control System 11

12. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 Monitors critical parameters of machine components Takes protective action without operator intervention Interlocks from - Magnets, Vac chamber & valves, DCCT, flow, temperature, search & scram 400+ parameters & 35 equations Safeguards by tripping RF and stopping injection In-house VME based design System V&V and extensive testing Fail safe system implementation Operational 24x7 12 Machine Safety Interlock System

13. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 13 Slow Orbit Feedback Control System The new Model Predictive Controller (MPC) based orbit control system is under testing Implementation over RT platform, Automatic system identification, Observer and Controller tuning features. Fast update rate, Guaranteed stability, Tight orbit control. Constrained optimization with device faults and model assisted BPI data pre qualification strategies. Multivariable active feedback control Sensors: 56 Beam position indicators (BPI) for Horizontal (x) as well as vertical (y) plane. Actuators: 40 Vertical and 48 Horizontal correctors. correction rate: Once in 15 seconds. PID controller with Singular Value Decomposition based correction algorithm with auto fault detection and system recovery/restoration features. Orbit maintained within the ± 30µm band in both the planes SOFB Server Module SOFB Client Module

14. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 14 Global Fast Orbit Feedback in Indus-2 Beam Position Error (microns) Horizontal Plane Vertical Plane MaxRMSMaxRMS Uncorrected4015209 Corrected12362 Achieved attenuation of 50 Hz component in beam orbit by ~ 5dB. Integration of global FOFB with SOFB is being tested. FOFB Control SchemeFast Orbit Correction – Hor. Plane

15. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 15 Vertical Test Stand (VTS) Control System Fig.1 : Scheme of VTS Control System Two layer scheme - PC/PLC as per Fermilab Hardware: Siemens S7-300 Family of PLC CPU and I/O Modules Software: WinCC & STEP-7 Instruments interfaced: -cryo temperature monitors with cernox sensors, Pt 100 -Liquid Helium Level sensor -Gamma radiation monitor User Authentication Data logging in SQL DB Data trending Warning & alarms Personnel Safety System & Interlock

16. Control Systems for Linacs IIFC Meeting RRCAT Presentation 24-25 Feb 2015 16 VME based control system No. of parameters ~100 Signal interface - isolated signals Control software: In assembly Language GUI and server programs in LabView. Independent machine and personnel safety interlocks modules. Protective actions on interlock failure - in hardware. ARPF Linac Control System GUI panel of ARPF Linac Control System

17. Control System Developments IIFC Meeting RRCAT Presentation 24-25 Feb 2015 17 Equipment Control Station VME Boards Intelligent RF ECM Utility Module

18. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 18 Technologies Microprocessors & Microcontrollers Digital Signal Processors (DSP) Programmable devices : CPLD & FPGA Platforms : VME, PXI, PLC High Resolution ADCs (24-bit) and DACs (18-bit) Boards Nanosecond delay generators Communications : Reflective memory, Ethernet, TCP/IP, Profibus,Modbus, RS232, RS485, GPIB, Optical Fiber communication Hardware SCADA : PVSS, EPICS, LabVIEW Languages : C, C++, Matlab, Java, Assembly RTOS : OS-9, VxWorks, LabVIEW RT Programmable Logic : VHDL, Verilog, Xilinx ISE, ModelSim, LabVIEW FPGA Web programming : HTML, Java, PHP Database: MS-SQL Server Code compliance : LDRA for C/C++ Operating Systems : Windows : 2000/XP/7, Server 2008 Linux : Ubuntu, CentOS, RedHat Software

19. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 19 Hardware development cycle Requirement specifications Design and Review Prototype development and testing Fabrication and acceptance testing Functional testing Software development cycle Requirement specification & analysis Design and Review Module development and unit level testing Integrated system testing System level testing I/O Board level test, Device driver level test, Process level test, Inter- process test, L-3 and L-2 Communication test Layer-2 and Layer-1 communication testing, Full integrated testing from GUI to Device Software Testing Functionality Testing OFF Line Testing ON Line Testing GUI Testing Testing variable bounds Checks on “File Loading” operation for invalid format System Development Methodology

20. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 20 Team with vast experience in accelerator control systems Expertise in design, development, testing, integration and upgradation Knowledge of most related technologies Completed control systems for 2.5 GeV SRS & other Accel. Already working on proton linac control systems PIP II under IIFC framework will be interesting Requirements: Get the FRS, decide the scope of work, understand the work methodology and TRS to estimate the time-lines Summary

21. IIFC Meeting RRCAT Presentation 24-25 Feb 2015 21 Summary