1. EPICS 2009, RRCAT January 28, 2009 Indus Controls Overview Pravin Fatnani (fatnani@rrcat.gov.in) Accelerator Controls RF Systems & Controls Division Raja Ramanna Centre For Advanced Technology (RRCAT), Indore

2. EPICS 2009, RRCAT January 28, 2009 Indus Accel. Complex: Schematic INDUS-2 TL-3

3. EPICS 2009, RRCAT January 28, 2009 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

4. EPICS 2009, RRCAT January 28, 2009 Accuracy and Stability of References to PS for Indus-2 S.No Reference for (Power Supply type) Accuracy & Stability Desired (Requirement) Accuracy & Stability Available (Provided) At Full scale 1Dipole Magnet P/Ss –I250 ppm15 ppm ( 0.0015% ) 2. Quadrupole Magnet P/Ss–I2 (Q1,Q2,Q3,Q4,Q5 types) 50 ppm15 ppm ( 0.0015% ) 3. Sextupole Magnet P/Ss –I2 (S1,S2,Sh, types) 1000 ppm60 ppm ( 0.0060% ) 4.Steering Magnets 500 ppm 60 ppm ( 0.0060% ) 5.All other Magnets of I2 and TL3500 ppm60 ppm ( 0.0060% )

5. EPICS 2009, RRCAT January 28, 2009 EC LAYEREC LAYER USER INTERFACE LAYER SC LAYER RS485RS485 P/S #2 ETHERNET SC FOR VACUUM P/S #8 P/S #1 CPU68040CPU68040 P R O F I #1 ETHERNETETHERNET CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD P/S #Q P/S #P P/S #R P/S #10 P/S #9 P/S #16 RS485RS485 RS485RS485 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 VACUUM  GAUGES  PUMPS  GATE VALVES WORK STATION # N (Pentium) CPU68040CPU68040 P R O F I #1 ETHERNETETHERNET CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD PROFIBUSPROFIBUS RS485RS485 CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD RS485RS485 RS485RS485 EIU #31 EIU #1 EIU #2 CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD PROFIBUSPROFIBUS INDUS-2 CONTROLS - Scheme & Data Flow 5 Indus Control System Essentials

6. EPICS 2009, RRCAT January 28, 2009 SC LAYER EC LAYEREC LAYER USER INTERFACE LAYER RS485RS485 P/S #2 ETHERNET SC FOR VACUUM P/S #8 P/S #1 CPU68040CPU68040 P R O F I #1 P R O F I #2 ETHERNETETHERNET P R O F I #3 CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD P/S #Q P/S #P P/S #R P/S #10 P/S #9 P/S #16 R S 4 8 5 RS485RS485 EC #N EC #1 EC #2 SC FOR MAG P/S WORK STATION # 2 (Pentium) WORK STATION # 1 (Pentium) WORK STATION # N (Pentium) CPU68040CPU68040 P R O F I #1 P R O F I #2 ETHERNETETHERNET P R O F I #3 CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD CPU 68KCPU 68K PROFIPROFI IOBOARDIOBOARD IOBOARDIOBOARD PROFI BUS Telegrams SCHEME OF INDUS-2 CONTROL SYSTEM

7. EPICS 2009, RRCAT January 28, 2009 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

8. EPICS 2009, RRCAT January 28, 2009 Software at Layer-1 Operator Console PVSS UI Operator Console PVSS UI EV API DM PVSS SYSTEM Data to/from local controller Data Ethernet

9. EPICS 2009, RRCAT January 28, 2009 PROFIBUSPROFIBUS TCP/IP Network SOS Profi-Master Aux Process1 Aux. Process2 Profi Master Board 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.

10. EPICS 2009, RRCAT January 28, 2009 PROFIBUSPROFIBUS Profi Slave I/O Proc 1 I/O Proc 2 I/O Proc 3 I/O Proc 4 Profi Slave Board Digital O/P Board (Relay) Digital I/P Board(Opto) Analog O/P Board (DAC) Analog I/P Board(ADC) PROFIBUSPROFIBUS 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

11. EPICS 2009, RRCAT January 28, 2009 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.

12. EPICS 2009, RRCAT January 28, 2009 ProfiBus Developments DP Master & Slave boards Master-Slave communication only Baud rate 750K

13. EPICS 2009, RRCAT January 28, 2009 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.

14. EPICS 2009, RRCAT January 28, 2009 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.

15. EPICS 2009, RRCAT January 28, 2009 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 CONTROLSCONTROLS

16. EPICS 2009, RRCAT January 28, 2009 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.

17. EPICS 2009, RRCAT January 28, 2009 An Overview of PVSS SCADA

18. EPICS 2009, RRCAT January 28, 2009 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

19. EPICS 2009, RRCAT January 28, 2009 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

20. EPICS 2009, RRCAT January 28, 2009 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

21. EPICS 2009, RRCAT January 28, 2009 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.

22. EPICS 2009, RRCAT January 28, 2009 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.

23. EPICS 2009, RRCAT January 28, 2009 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.

24. EPICS 2009, RRCAT January 28, 2009 Managers Overview

25. EPICS 2009, RRCAT January 28, 2009 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 EV DM

26. EPICS 2009, RRCAT January 28, 2009 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

27. EPICS 2009, RRCAT January 28, 2009 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.

28. EPICS 2009, RRCAT January 28, 2009 PVSS API & GUI for Indus-2 Control System

29. EPICS 2009, RRCAT January 28, 2009 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.

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

31. EPICS 2009, RRCAT January 28, 2009 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.

32. EPICS 2009, RRCAT January 28, 2009 API Manager in Indus-2 Control System SC layer ( L2) VME SC layer ( L2) VME PVSS Server API DBEV UI Panel UI

33. EPICS 2009, RRCAT January 28, 2009 Number of Parameters Handled System NameNo of Signals (approx) MPS 4200 Vacuum 1600 RF 400 Timing 100 BDS 500 RSSS 300 BLFE 300 Interlock 250 Orbit Correction Total 200 ~8000

34. EPICS 2009, RRCAT January 28, 2009 Few screenshots (MPS)

35. EPICS 2009, RRCAT January 28, 2009 RF

36. EPICS 2009, RRCAT January 28, 2009 BLFE

37. EPICS 2009, RRCAT January 28, 2009 Vacuum

38. EPICS 2009, RRCAT January 28, 2009 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

39. EPICS 2009, RRCAT January 28, 2009 INDUS-2 LCW Plant Control Software Architecture Ethernet RS-485 VME serviceRS-485 serviceCom. service Data log serviceGlobal data table Debug serviceControl service GUI service Event service Configuration Files for defining system state Help serviceAccess control and maintenance/repair management service Module for Redundancy PVSS data publish service Configuration data table generation service

40. EPICS 2009, RRCAT January 28, 2009 Indus 2 RGA system main GUI Panel

41. EPICS 2009, RRCAT January 28, 2009 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.

42. EPICS 2009, RRCAT January 28, 2009 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.

43. EPICS 2009, RRCAT January 28, 2009 CONTROLSCONTROLS 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 )

44. EPICS 2009, RRCAT January 28, 2009

45. Web Based Applications Online Machine Status Display System Machine History Data Query Fault Information System E-Log-Book

46. EPICS 2009, RRCAT January 28, 2009 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.

47. EPICS 2009, RRCAT January 28, 2009 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)

48. EPICS 2009, RRCAT January 28, 2009 Screenshot: Indus OnLine (Synoptic Display)

49. EPICS 2009, RRCAT January 28, 2009 Screenshot: Indus OnLine (Data Query Form)

50. EPICS 2009, RRCAT January 28, 2009 Screenshot: Indus OnLine (Data Query Result)

51. EPICS 2009, RRCAT January 28, 2009 Screenshot: Indus OnLine (Data Query Form)

52. EPICS 2009, RRCAT January 28, 2009 Screenshot: Indus OnLine (Data Query Result)

53. EPICS 2009, RRCAT January 28, 2009 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

54. EPICS 2009, RRCAT January 28, 2009 Screenshot: Indus Machine Status Display

55. EPICS 2009, RRCAT January 28, 2009 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

56. EPICS 2009, RRCAT January 28, 2009 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.

57. EPICS 2009, RRCAT January 28, 2009 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.

58. EPICS 2009, RRCAT January 28, 2009 Screenshot: FIS (Fault Logger)

59. EPICS 2009, RRCAT January 28, 2009 Screenshot: FIS (Fault Acknowledger)

60. EPICS 2009, RRCAT January 28, 2009 Screenshot: FIS (Fault Explorer Query Result)

61. EPICS 2009, RRCAT January 28, 2009 Screenshot: FIS (Fault Analyzer)

62. EPICS 2009, RRCAT January 28, 2009 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.

63. EPICS 2009, RRCAT January 28, 2009 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.

64. EPICS 2009, RRCAT January 28, 2009 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.

65. EPICS 2009, RRCAT January 28, 2009 RELAY OUTPUT BOARD 32 relay contact outputs, isolated and potential free. O/P status indication. Address selection through DIP switches.

66. EPICS 2009, RRCAT January 28, 2009 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.

67. EPICS 2009, RRCAT January 28, 2009 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.

68. EPICS 2009, RRCAT January 28, 2009 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.

69. EPICS 2009, RRCAT January 28, 2009 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.

70. EPICS 2009, RRCAT January 28, 2009 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.

71. EPICS 2009, RRCAT January 28, 2009 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.

72. EPICS 2009, RRCAT January 28, 2009 Thank You.