Controls Renovations AB-PO

Controls RenovationsAB-PO

Quentin KingDaniel CalcoenStephen PageDecember 3rd 2008

Power Converter Controls Renovations 23/12/2008

Power Converter Controls Renovations Overview CPS: Main Power Converter Booster: CAMAC controlled dipoles and multipoles PS Complex:

G64 / CAMAC G64 / MIL1553 RS422 controlled converters PLC controlled converters

SPS and LHC/NA transfer lines Central Interlock System (CIS) PLC MUGEF for Main Power Converters MUGEF for Auxiliary Power Converters Junction Crate converters in the North Area

FGC1 converters FESA & GM Classes

Power Converter Controls Renovations 3

After more than 40 yearsit’s zoo of differentspecies of controlselectronics:

Renovation priority: CPS MPS CAMAC hardware GM classes

Overview of converter controls

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MIL1553; 1288

CA-MAC; 235

PLC; 466RS42

2; 322

Junc-tion

Crate; 346

MUGEF; 616

Total3273

GM

FESA

FGC1740


Work Package Summary

Work Package start date end date specific controls hw (KCHF)

CO controls hw(KCHF)

total SW resources (FTE) Comments

PS MPS Upgrade Q1/2008 Q2/2009 10 3 1 New application required

POPS Q3/2009 Q1/2010 10 3 0.2 Same SW as PS MPS

Booster Upgrade I Q4/2008 Q2/2009 16 5 1 New application required

Booster Upgrade II Q4/2009 Q2/2010 280 40 0.2 Same SW as phase I

MUGEF MPC Q4/2009 Q2/2010 125 0 0.2 No change to applications

SPS CIS GUI Q1/2008 Q1/2010 0 2 1 New PVSS interface

CAMAC elimination - - 0 150 0.1 Replace CAMAC with MIL1553

REX TRAP Q1/2008 ? ? ? ? Waiting for GFAS/Timing

FESA Gateways Q1/2008 Q1/2010 - - 1 RS422/PLC/MIL1553

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CPS Main Power Supply

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CPS MPS Controls Renovation New POPS (POwer for PS) converter will be installed in

2009 for operation in 2010 New FGC2 controls electronics developed for POPS has

also been installed now for the existing PS MPS The legacy controls electronics is very old and difficult to

support. There is a spare legacy system but it could take some time to make it work.

The FGC based controls enable direct regulation of the field for the first time making operation more deterministic

Access to the new FGC PS_MPC class is via JAPC replacing the special GM class

Members of OP will write the application

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Booster dipole/multipole renovation

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Booster dipole/multipole renovation The CAMAC controls hardware for the 144 systems is

obsolete and very difficult to support The power electronics is also obsolete All the dipole and multipole converters must share 8

waveforms using individual gain factors. This limits the performance of the booster.

A new compact switched mode converter has been developed by AB-PO

8 converters will be installed and tested with non-essential circuits in 2009

The remaining 136 systems will be installed for 2010 This will be the first application to use the new FGC3

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FGC3 Electronics

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FGC3 Electronics Electronics for new power converters in the booster and future

machines (Linac4) and future renovations (North Area?) Smaller (3U x 12TE), cheaper (1.5KSF) and more powerful than

the FGC2 Memory is not protected against single bit errors so operation in

radiation is excluded The FGC is responsible for more functionality than the existing

G64 bus based controls:

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Functionality G64 FGCNetwork: CAMAC/MIL1553 WorldFIP

Timing: TG8 CTRI in Gateway

Function Generation: GFAS FGC

Acquisition: Sampler/OASIS FGC

State Control: G64 CPU FGC


FGC3 Electronics Three FGC3 software classes are foreseen:

Class 61 – Power converters with an analogue voltage loop Class 63 – Power converters with a digital voltage loop Class 64 – Capacitor discharge converters

The network for the Booster renovation will be the standard 2.5 Mbps WorldFIP used in the LHC.

The FGC WorldFIP gateways in the Booster will be based on the new PC based Front-End platform but the software will be identical to the LHC FGC gateways

For future machines such as Linac4 we would like to have a WorldFIP-like protocol over 1GB Ethernet (White Rabbit based)

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Help needed from CO Installation of first FGC WorldFIP gateway and one

segment for the pre-series tests in 2009 Installation of four other gateways and WorldFIP

segments for operation in 2010

Open question: Who will integrate the new FGC Class 61 properties into the

Working Sets application (and later into INCA?)

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G64 / CAMAC

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CAMAC controlled systems (235)

PSB; 146

CTF3; 84

Test; 5

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2 systems forthe PSB sextupole

and octupoleconverters


G64 / CAMAC 127 G64 bus based converter control systems are still

driven from CAMAC crates The G64 CAMAC serial link (STE) interfaces are

obsolete and difficult to repair. CO is responsible for the CAMAC but in practice

provides no support for the STE interfaces. AP-PO is forced to repair broken cards.

Communication with the CAMAC crate is via a GM class in a VME crate

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G64 / CAMAC – what to do? The converters in CTF3 will be required for several more

years. The G64 software can work with either CAMAC or

MIL1553 links so changing the STE interface for a MIL1553 (RTI) interface would solve the problem with little effort from AB-PO

CO needs to decide if it wants to continue to support CAMAC or to install MIL1553 instead

If CAMAC remains then the POW GM class will need to be ported to FESA

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G64 / MIL1553 Controls

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MIL1553 controlled systems (1288)

PSB; 212

CPS; 379

ADE; 298

CNGS; 2

Linacs; 244

LEIR; 71

ISOLDE; 3

CTF3; 79

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G64 / MIL1553 G64 bus based system providing converter state control,

status readout and set point control for converters that do not require a GFAS for function generation

Controlled using POW-V GM class FESA class in preparation but blocked waiting for property

model MIL1553 will be used for many more years (probably 10 or

more) CO are developing a new CBMIA card which will be the

MIL1553 bus master for the new PCI based hardware platform.

The RTI MIL1553 interface must also be supported for many years and new cards will be needed if the CAMAC links are replaced with MIL1553.

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RS422 controlled Converters

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RS422 controlled Converters (322)

LEIR; 233

CTF3; 63

Rex; 26

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RS422 controlled Converters These small cost-effective converters include the

controls electronics and use RS422 links to a VME front-end

No hardware renovation foreseen Two different FESA classes were written: RexDanfysik

for Rex and PowDf7000 for LEIR (also used in CTF) In the medium term, these will be unified into one class,

perhaps targeting the new PC based front end

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PLC controlled converters

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PLC controlled converters

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PLC controlled converters (466)LEIR; 11

ISOLDE; 402

Rex; 53

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PLC controlled converters PLCs are used for simple power converters (typically

HV) in LEIR, Isolde and REX A small number of new PLC controlled converters will be

installed in AD for operation from 2009 REX uses RexPowP FESA class (V2.8) Isolde and LEIR still use PowP GM class Migration to FESA will need effort from AB-PO and also

from the applications developers A single FESA class will cover REX and the other

machines

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SPS Central Interlock System (CIS)

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SPS Central Interlock System (CIS) Replacement of obsolete HP workstations for the GUI by

PVSS will not be completed for 2009 Existing GTD interface must be used for one more year HP’s are no longer supported but a number of spares are

available The PVSS interface must be ready for 2010 but this

depends upon the new Industrial Controls and Electronics group of the EN department

There is a project to renovate the power part of the main power converters

This renovation is not expected to significantly change the CIS but there will certainly be some modifications to the signals at the level of the individual converters

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MUGEF for the SPS Main Converters

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MUGEF for the SPS Main Converters The SPS main converter controls has 4 high resolution

channels for RMB, RQD, RQF1, RQF2 This is a special MUGEF system with a high resolution

ADC card (MAM) and high resolution function generation linked by fibres to the analogue current regulation electronics

The standard MUGEF FESA class runs on this crate. There is an on-going program of improvements to this

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MUGEF for the SPS/Transfer Lines

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MUGEF for the SPS/Transfer Lines There are 19 standard MUGEF systems based on VME

crates with RIO2 CPU boards MUGEF software is accessed via SL-EQUIP or a FESA

2.10 class The last major hardware upgrade was 10 years ago The converter command and status interface will be

replaced in 2010 The RIO2 CPU board is slow and has a small memory –

a more modern Intel based CPU would nice but porting to LINUX will take some work

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SPS North Experimental Area

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SPS North Experimental Area 346 converters in the SPS north area are controlled

using three Junction Crate systems. The systems run FESA 2.10 There are no plans to renovate the systems but the

controls electronics could be upgraded to use FGC3 systems for about 1MSF

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FGC1 (DICO) Controlled Converters

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FGC1 (DICO) Prototype controls for the LHC power converters 76 produced in 2000 for String-2 and Magnet Test Bench

power converters in SM18 Still used in SM18, Block 4, CAST (till end 2010) Software is only partially compatible with the FGC2s Still supported though no development expected These systems will probably be used for several more

years

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FESA and GM Classes Open issues:

The PO group is responsible for: Porting the GM PowP class to FESA PO_PLC class Porting the GM Pow-V class to FESA PO_MIL1553 class

However, the “users” must help to specify the property model that they want to represent the power converters

RS422 gateways are sometimes shared with other users (e.g. sampler) and all the FESA classes must share the same version of FESA. Can we have front-end systems dedicated to just one purpose?

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FESA and GM Classes Open issues:

At least three middle tier GM classes exist which sit on top of the old Pow-V and PowP GM classes:

HRSMAG LINC ISOPOW

The people responsible for these GM classes will need to port them to use the new PO_M1553 and PO_PLC FESA classes when the migration to FESA takes place

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http://oraweb.cern.ch/pls/abc/w3gm.gmclass?class=hrsmag

http://oraweb.cern.ch/pls/abc/w3gm.gmclass?class=linc

http://oraweb.cern.ch/pls/abc/w3gm.gmclass?class=isopow


What role could the FGC3 play? It is conceivable to replace the electronics for more converters in

the PS complex with the FGC3 however there is a material and personnel cost

For example, the LPS1 and LPS2 converters could be driven by FGC3 provided an interlock card is developed

The personnel costs for development might be 1FTE + prototyping costs (i.e. ~200KSF)

The materials cost would be ~2.5KSF per converter The installation cost would depend upon the solution chosen and

might about around 500SF. For CTF3 with 84 systems this would be 200KSF + 84x3KSF =

~450KSF + WorldFIP cabling and gateways Question: would this be cheaper than replacing the CAMAC with

MIL1553? Answer: No.

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Summary At this time there are many parallel renovation projects,

especially related to porting of GM to FESA Resources in PO (as everywhere else) are limited and

priorities must be set globally and efforts coordinated Two FTE working on FESA/FGC classes We are ready to do our part to migrate to InCA/FESA but

the timescales will have to be realistic given the effort available and our commitment to existing projects such as LHC radiation tests and Linac4 controls

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Documents

Controls Renovations AB-PO