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 l Four layers of protection! »HardwarePLC »Hardware / Software(Fast Protect Latched) »Hardware / Software(Fast Protect Auto Reset) »Software (Run Permit System) l Machine Protection System is not a “Safety Class” or “Safety Significant” System. l SNS will be built and commissioned in Phases, MPS must accommodate this schedule, (Flexible and Reliable). l Reliability – The Machine Protection System must inhibit the beam when required. It must fail in a SAFE state. l 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 l Run Permit System (1 second) »Verifies IOC configuration and beam line equipment status. »MPS masking, Beam Power limit verification l Fast Protect Auto Reset (20 microseconds) »Beam Loss Monitors »Beam Current Monitors l Fast Protect Latched System (20 microseconds) »Power Supply status, RF, Kicker status »System cooling status (Collimators, dumps, etc) »etc. l MPS PLC (~ 33 msec) »Magnetic Field limit(s) verification »Beam Dump monitoring

SNS Integrated Control System Machine Availability l MODE masks are defined by MPS and Operations, not easily changed. l Allows beam when invasive diagnostics are used only for SAFE beams. l Easy OPI for verifying Mode Masks. l Mode masks are applied pulse to pulse from timing system l 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 l Machine Modes »MEBT Beam Stop »CCL Beam Stop »Linac Dump »Injection Dump »Ring »Extraction Dump »Target l Beam Modes »Diagnostics (10 usec) »Diagnostics (50 usec) »Diagnostics (100 usec) »Full Pulse Width (1 msec) »Full Power (Depends on Dump) l 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 l RTDL Heartbeat (PCI Clock) l Event link heartbeat l Driver – IOC heartbeat l Hardware Configuration file checks against actual HW settings l 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/ ) l Mode Masks »mask + /mask>>8 (single bit upset errors) »Software verification of masks (Configuration control) »Checksum of masks (File integrity) l Cable Status monitored

SNS Integrated Control System MPS Hardware l Technobox PMC reconfigurable IO card l 10K70 Altera l (20k200 newer) l Up to 5 per IOC with PMC_Span, 16 inputs each

SNS Integrated Control System MPS PMC Module (Also nice generic digital IO module)

SNS Integrated Control System MPS Fast Protect System Layout

SNS Integrated Control System MPS Input Summary (August 5005) l 27 new chassis installed l Copper phased out, using fiber l Post CD4, corrector PS status will be used l Inputs will quadruple for CD4

SNS Integrated Control System MPS – PLC Control Net Layout

SNS Integrated Control System PLC Remote Inputs l Machine made, Beam Mode selection l Emergency Crash l Trigger Control sanity checks l Timing System handshakes l Target (or Dump) Status »Pressure, Temperature »Flow, Vacuum status l 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 l Beam Current Monitor (Not in baseline, Hardware chosen) »P-P Pulse Width verification »Beam Power, Integrated Beam Current l No direct current density or beam position monitors on dump windows or target

SNS Integrated Control System Run Permit (Software) Layers l Configuration Control »Mode masks »SW masks »EPICS db’s »Archiver files »Alarm Handler (?) »Timing System db’s l Post Mortem »First fault »Waveform viewer l Software monitoring »PS’s Field »RF, Phase and amplitude »BLM HV l Selected set point limits l Timing System pattern generator l Integrated Beam Loss (software MPS trip)

SNS Integrated Control System MPS Applications l First hit and total trips entered every day at midnight l MPS First Hit stats since Sep 19, :00:00 RFQ_LLRF:HPM1:FPAR_Src_chan_status, counts = 2806 DTL_LLRF:HPM5:FPAR_CCL_BS_chan_status, counts = 2176 DTL_LLRF:HPM6:FPAR_CCL_BS_chan_status, counts = 755 CCL_MPS:FPAR_Sublink04D:FPAR_CCL_BS_chan_status, counts = 624 l Noise was initially a big problem. Noise reduction, filters, fiber installations have mostly eliminated the problem. l MPS First fault – Now runs as server – client application l Detects first fault, tracks total # faults

SNS Integrated Control System MPS Applications l Input Status Summary »Shows input status and consequences of changing beam modes or machine modes. l Mode Mask Verification »Replaces spreadsheet, paper and pencil »Replaces tedious task of verifying 35 modes per input * 350 inputs = individual checks l 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 l 3D Waveform viewers »BLM waveform vs. time or accelerator location l Scope Application (Correlated waveforms) »RF vs BLM waveforms »Injection / Extraction kickers vs BLM »BCM vs. BLM l Post Mortem Tools »First fault »BLM loss model vs component »BLM waveform signatures (Archive waveform viewer) –Fast vs Off Energy vs Halo l MAID (Maximum allowable intra pulse difference) – Full Power operation »Verifies beam to target parameters acceptable before allowing next pulse (or as fast as possible) l Beam Scheduler / pattern generator