SNS Integrated Control System

SNS Machine Protection System

EPICS Workshop

April 27, 2005

Coles Sibley

SNS Integrated Control System

Intro

1. System overview

2. Hardware summary

3. Input Summary

4. Software tools

5. Configuration Control

6. Tools needed for MPS

What to avoid.

SNS Integrated Control System

MPS Design Assumptions

Four layers of protection!» Hardware PLC» Hardware / Software (Fast Protect Latched)» Hardware / Software (Fast Protect Auto Reset)» Software (Run Permit System)

Machine Protection System is not a “Safety Class” or “Safety Significant” System.

SNS will be built and commissioned in Phases, MPS must accommodate this schedule, (Flexible and Reliable).

Reliability – The Machine Protection System must inhibit the beam when required. It must fail in a SAFE state.

Availability – The machine availability should be as high as possible. The MPS must be easy to configure and have a “friendly” operator interface. False trips must be minimized.

SNS Integrated Control System

Layers of Protection

Run Permit System (1 second)» Verifies IOC configuration and beam line equipment status.» MPS masking, Beam Power limit verification

Fast Protect Auto Reset (20 microseconds)» Beam Loss Monitors» Beam Current Monitors

Fast Protect Latched System (20 microseconds)» Power Supply status, RF, Kicker status» System cooling status (Collimators, dumps, etc)» etc.

MPS PLC (~ 33 msec)» Magnetic Field limit(s) verification» Beam Dump monitoring

SNS Integrated Control System

Machine Availability

MODE masks are defined by MPS and Operations, not easily changed.

Allows beam when invasive diagnostics are used only for SAFE beams.

Easy OPI for verifying Mode Masks.

Mode masks are applied pulse to pulse from timing system

Allow easy bypass (Software Masking) for selected inputs

» Different rules for commissioning and operations

» Commissioning, FPAR devices can be masked

» Commissioning, FPL – subset of Quads can be masked, all dipoles and rest of quads need ASD Operations approval.

SNS Integrated Control System

Machine / Beam Mode Definitions

Machine Modes

» MEBT Beam Stop

» CCL Beam Stop

» Linac Dump

» Injection Dump

» Ring

» Extraction Dump

» Target

Beam Modes

» Diagnostics (10 usec)

» Diagnostics (50 usec)

» Diagnostics (100 usec)

» Full Pulse Width (1 msec)

» Full Power (Depends on Dump)

Machine mode selected by Key switch in control room, Beam Mode selected by Key or software. Switches read by MPS PLC system.

SNS Integrated Control System

MPS Timing System checks

RTDL Heartbeat (PCI Clock) Event link heartbeat Driver – IOC heartbeat Hardware Configuration file checks against actual HW settings Machine / beam mode (< 3.3e-10 probability of undetected fault)

» 8 bit CRC (1/256)» 8b bits encoded in 24 bit frame for single bit errors» 24 bit CRC on all frames (1/16777215)

Mode Masks» mask + /mask>>8 (single bit upset errors)» Software verification of masks (Configuration control)» Checksum of masks (File integrity)

Cable Status monitored

SNS Integrated Control System

MPS Hardware

Technobox PMC reconfigurable IO card

10K70 Altera

(20k200 newer)

Up to 5 per IOC with PMC_Span, 16 inputs each

SNS Integrated Control System

MPS PMC Module (Also nice generic digital IO module)

PCI to LocalSlave

Bus Bridge

ProgramablePLL ClockGenerator

AlteraFLEX 10K

FPGA

2 - 100 nsec5 tap Delay

lines

128K x 16SRAM

SpecialReceiver

74FCT16245Buffers

Serial EPROM

68 Pin Front PanelConnector

64 Pin (P2)Rear IO connector

32 bit PCI Bus

16 Data

96

2

322

xx MHz

1 5

18 Addr12

64

33MHz

+5

1 5

Technobox Reconfigurable Digital IO PMC

SNS Integrated Control System

MPS Fast Protect System Layout

RING

RFQDrive

HEBT

Ldump

SRF

CCL

DTL

65 kV

RFQHVPPS

MPS Inputs

MPS Inputs

MPS InputsMPS Inputs

MPS Inputs

MPS Inputs

MPS Inputs

MPSMaster

Machinemode

RING

RTBT

Xdump

MPS Inputs

MPS Inputs

MPS Inputs

Idump

RTBT

Target

5.6 us 5.8 us 8.2 us 8.2 us

MEBTMPS Inputs

RFQ

LEBT

Src

MPS Inputs

MPS Inputs

MPS Inputs

0.8 us

MPS Inputs

MPS Inputs

SNS Integrated Control System

MPS Input Summary (August 5005)

MPS Inputs MEBT_BS CCL_BS L_Dmp MEBT_BS CCL_BS L_Dmp

IBCM 1

BLM / ND 66 129 66 129

Beam Stop / Dump 2 4 6 2 4 6Intercepting diagnostics 11 27 6 11 27 6

Power Supplies 11 15 52 11 61 90

Vacuum 3 8 10 3 8 10

RF Systems 11 26 104 11 26 104

MPS inter connects 9 4 6 9 4 6DBCM 6

Totals 47 150 313 48 202 351

Commissioning POST CD4

27 new chassis installed

Copper phased out, using fiber

Post CD4, corrector PS status will be used

Inputs will quadruple for CD4

SNS Integrated Control System

MPS – PLC Control Net Layout

P P SE N T R Y

MEBTBS

LDMP

IDMP

RING

EDMP

TGT

MPSPLC

PPS

ZO

NE

Sta

tus

65 KVPSRFQ-RFRFQ-PS

Plasma-RF

Control Net - Flex IO Redundant Network - Fast Diagnostics

CCLBS

Avg. IPWmon

PSMon

PSMon

ImonMachine ModeBeam Mode

SelectKey switch

Typical DmpTC's, H2OVacuum

SNS Integrated Control System

PLC Remote Inputs

Machine made, Beam Mode selection

Emergency Crash

Trigger Control sanity checks

Timing System handshakes

Target (or Dump) Status» Pressure, Temperature» Flow, Vacuum status

Power supply current monitor’s» Quads – Hi window, Dipoles, Hi and Off windows.» Steering corrector’s – Window (RTBT only)

SNS Integrated Control System

Injection Dump inputs

Beam LossMonitor

BeamCurrentMonitor

QuadCurrentWindow

Comparator

WireScanner

InjectionDumpStatus

FastValve

HarpSEM

Beam Current Monitor (Not in baseline, Hardware chosen)» P-P Pulse Width verification» Beam Power, Integrated Beam Current

No direct current density or beam position monitors on dump windows or target

SNS Integrated Control System

Run Permit (Software) Layers

Configuration Control» Mode masks» SW masks» EPICS db’s» Archiver files» Alarm Handler (?)» Timing System db’s

Post Mortem» First fault» Waveform viewer

Software monitoring» PS’s Field» RF, Phase and amplitude» BLM HV

Selected set point limits

Timing System pattern generator

Integrated Beam Loss (software MPS trip)

SNS Integrated Control System

MPS Applications

First hit and total trips entered every day at midnight MPS First Hit stats since Sep 19, 2004 00:00:00

RFQ_LLRF:HPM1:FPAR_Src_chan_status, counts = 2806DTL_LLRF:HPM5:FPAR_CCL_BS_chan_status, counts = 2176DTL_LLRF:HPM6:FPAR_CCL_BS_chan_status, counts = 755CCL_MPS:FPAR_Sublink04D:FPAR_CCL_BS_chan_status, counts = 624

Noise was initially a big problem. Noise reduction, filters, fiber installations have mostly eliminated the problem.

MPS First fault – Now runs as server – client application

Detects first fault, tracks total # faults

SNS Integrated Control System

MPS Applications

Input Status Summary» Shows input status and

consequences of changing beam modes or machine modes.

Mode Mask Verification» Replaces spreadsheet,

paper and pencil» Replaces tedious task of

verifying 35 modes per input * 350 inputs = 12250 individual checks

Automated Verification (in progress)

» Check inputs» Trip and verify MPS» Reset, turn back on» Generate report to e-log

SNS Integrated Control System

MPS Bypass Request

Enter new bypass request

Edit request

Approve request

Install request

Remove request

View existing Open request’s

View history

SNS Integrated Control System

Software tools needed 3D Waveform viewers

» BLM waveform vs. time or accelerator location

Scope Application (Correlated waveforms)» RF vs BLM waveforms» Injection / Extraction kickers vs BLM» BCM vs. BLM

Post Mortem Tools» First fault» BLM loss model vs component» BLM waveform signatures (Archive waveform viewer)

– Fast vs Off Energy vs Halo

MAID (Maximum allowable intra pulse difference) – Full Power operation

» Verifies beam to target parameters acceptable before allowing next pulse (or as fast as possible)

Beam Scheduler / pattern generator