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Controls Renovations AB-PO

Controls Renovations AB-PO. Quentin King Daniel Calcoen Stephen Page December 3 rd 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

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Controls Renovations AB-PO

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  1. Controls RenovationsAB-PO Quentin King Daniel Calcoen Stephen Page December 3rd 2008

  2. 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. Overview of converter controls FGC1740 FESA GM • After more than 40 yearsit’s zoo of differentspecies of controlselectronics: • Renovation priority: • CPS MPS • CAMAC hardware • GM classes Power Converter Controls Renovations

  4. Work Package Summary Power Converter Controls Renovations

  5. CPS Main Power Supply Power Converter Controls Renovations

  6. 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 Power Converter Controls Renovations

  7. Booster dipole/multipole renovation Power Converter Controls Renovations

  8. Booster dipole/multipole renovation The CAMAC controls hardware for the 144 systems is obsolete and very difficult to support The power electronics is also obsolete All the dipole and multipole converters must share 8 waveforms using individual gain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 controls electronics Power Converter Controls Renovations

  9. FGC3 Electronics Power Converter Controls Renovations

  10. 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: Power Converter Controls Renovations

  11. 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) Power Converter Controls Renovations

  12. 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?) Power Converter Controls Renovations

  13. G64 / CAMAC Power Converter Controls Renovations

  14. CAMAC controlled systems (235) 2 systems for the PSB sextupole and octupole converters Power Converter Controls Renovations

  15. 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 Power Converter Controls Renovations

  16. 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 Power Converter Controls Renovations

  17. G64 / MIL1553 Controls Power Converter Controls Renovations

  18. MIL1553 controlled systems (1288) Power Converter Controls Renovations

  19. 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. Power Converter Controls Renovations

  20. RS422 controlled Converters Power Converter Controls Renovations

  21. RS422 controlled Converters (322) Power Converter Controls Renovations

  22. 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 Power Converter Controls Renovations

  23. PLC controlled converters Power Converter Controls Renovations

  24. PLC controlled converters Power Converter Controls Renovations

  25. PLC controlled converters (466) Power Converter Controls Renovations

  26. 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) Isoldeand 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 Power Converter Controls Renovations

  27. SPS Central Interlock System (CIS) Power Converter Controls Renovations

  28. 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 Power Converter Controls Renovations

  29. MUGEF for the SPS Main Converters Power Converter Controls Renovations

  30. 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 Power Converter Controls Renovations

  31. MUGEF for the SPS/Transfer Lines Power Converter Controls Renovations

  32. 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 Power Converter Controls Renovations

  33. SPS North Experimental Area Power Converter Controls Renovations

  34. 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 Power Converter Controls Renovations

  35. FGC1 (DICO) Controlled Converters Power Converter Controls Renovations

  36. 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 Power Converter Controls Renovations

  37. 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? Power Converter Controls Renovations

  38. 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 Power Converter Controls Renovations

  39. 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. Power Converter Controls Renovations

  40. 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 Power Converter Controls Renovations

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