CERN TE-MPE Jonathan Búrdalo Gil MARCH 2013 OVERVIEW OF ITER USER INTERFACE BOX EDMS 1283934

CERN TE-MPEJonathan Búrdalo Gil MARCH 2013

OVERVIEW OF ITER USER INTERFACE BOX

EDMS 1283934

CERN

TE-MPE-TM 28th March 2013

Outline

2

Motivation and overview

Discharge Loop Interface Box in detail

First prototype

Second prototype

Profinet

[11]

CERN


Outline

3

[11]



First prototype

Second prototype

Profinet

CERN


Motivation

4

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Protection system:Monitoring + Actuators

If Monitoring detects a fault:Actuators switch off system

1 single link is not reliable enough.2 redundant links provide required safety

ITER Magnets offer a different challenge:Maximize availability

Minimize fast discharges

Therefore, study of other architectures (2oo2,1oo3, 2oo3, etc).

M M M

A A A

CERN TE-MPE-EP Jonathan Búrdalo [email protected]

5

INTE

RFAC

E 11

INTE

RFAC

E2..1

0

INTE

RFAC

E1

PROFIBUS DP / PROFISAFE

IM 153-2H

IM 153-2H

SYNCHRO. LINK

SM 326F

10FDO

2xPS per CPU2x PS Periphery (SITOP)

2x CPU 414HF2x Comm. Proc.

2x Profibus networksStep7 + AWL + CFC +S7 F SW

ET200M

SM 326F 24D

I

SM 336FAI 6FAI

SM 322 D

O

8RO

IM 153-2H

IM 153-2H

SM 326F

10FDO

ET200M

SM 326F 24D

I

SM 336FAI 6FAI

SM 322 D

O

8RO

SM 323

8 DID

O

IM 153-2H

IM 153-2H

SM 326F

10FDO

SM 326F 24D

I

SM 336FAI 6FAI

SM 322 D

O

8RO

SM 331

8 AI

QD FDU 1..9 PC

QD FDU 1..9 PC

QD FDU 1..9 PC

SAME 11 INTERFACES FOR DIFFERENT USERS

CERN


Outline

6



First prototype

Second prototype

Profinet

[11]

CERN


DLIB: Purpose

7

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• Roles: • Simple interface for user signals with the 2oo3 discharge loops.• Transmit fast discharge requests to different users.• Galvanic Isolation between Users and PLC.

• Unique way of dealing with client diversity (ie. different interlocks systems, electronics, voltages…).• Independent of upgrades at the user side.

• Responds to required dependability and provides safe and reliable interlocking in both directions.

• Simplified test and commissioning (common diagnostics and monitoring).

• Remote test facility as from the level of the client connection.

CERN


DLIB: General Diagram

8

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DL+ IN

DL+ OUT

DL- IN

DL- OUT

FROM_USER +/-

TO_USER +/-OPTOCOUPLER OPTOCOUPLERTRIGGER SCHMIDT

OPTOCOUPLER

2oo3 LOGIC

LOOP BREAKER(Optocoupler)

TRIGGERSCHMIDT

TRIGGER SCHMIDT

TRIGGER SCHMIDT

FPGA(Test &

Monitoring)PROFINET

TestControlTestPattern

RELAY

CERN


DLIB: How does it work?

9

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DL+ IN

DL+ OUT

DL- IN

DL- OUT

FROM_USER +/-


OPTOCOUPLER

2oo3 LOGIC


TRIGGERSCHMIDT

TRIGGER SCHMIDT

TRIGGER SCHMIDT

FPGA(Test &

Monitoring)PROFINET


RELAY

CERN


DLIB: from USERS to Interface

10

• Users send status through 3 independent Current Loops.• Current limited by the interface box (fixed current source).• Design used at CERN with success (more than 220 similar

interface boxes in use).• 2oo3 Logic opens discharge loop.

CERN



11

DL+ IN

DL+ OUT

DL- IN

DL- OUT

FROM_USER +/-


OPTOCOUPLER

2oo3 LOGIC


TRIGGERSCHMIDT

TRIGGER SCHMIDT

TRIGGER SCHMIDT

FPGA(Test &

Monitoring)PROFINET


RELAYTVS

TVS

CERN


DLIB: from Interface to USERS

12

• Transmit to user the status of the discharge loop links.

• 1 to 1 because of dependability requirements. • Users MUST make the 2oo3 evaluation of the signals. • Optocoupler acting as dry contact and galvanic

isolation with the User

CERN



13

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DL+ IN

DL+ OUT

DL- IN

DL- OUT

FROM_USER +/-


OPTOCOUPLER

2oo3 LOGIC


TRIGGERSCHMIDT

TRIGGER SCHMIDT

TRIGGER SCHMIDT

FPGA(Test &

Monitoring)PROFINET


RELAYTVS

TVS

CERN


DLIB: Test and Monitoring

14

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• The Prototype V1 Interfaces had a Profibus slave.• V2 uses PROFINET with a new ASIC called TPS-1.• 16 bits of data in each direction.• Status of discharge loop, clients and extra info (temp,

use of 2oo3 logic, configuration…).• Managed by FPGA, Actel ProASIC3.• Due to time stamping limitations of this solution, and

the availability of a new chip, Prototype V2 uses a ITER compliant solution based on Profinet (Industrial Ethernet based Fieldbus).

CERN



15

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DL+ IN

DL+ OUT

DL- IN

DL- OUT

FROM_USER +/-


OPTOCOUPLER

2oo3 LOGIC


TRIGGERSCHMIDT

TRIGGER SCHMIDT

TRIGGER SCHMIDT

FPGA(Test &

Monitoring)PROFINET


RELAYTVS

TVS

CERN


DLIB: Connectors

16

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• Use compact and fully enclosed mechanics.• BURNDY connectors offer good EMC and

dependability.• 8 and 12 pins, male and female, to avoid

misconnections.• Diagnostics port in front panel for monitoring with

Profinet.

CERN


Outline

17



First prototype

Second prototype

Profinet

[11]

CERN


Experience from first Prototype

18

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• The first prototype was assembled and tested thoroughly. • Small test board with switches and LEDs to simulate the

discharge loop and the users (at 24 V and 5 V).• Everything “analogue” works according to specifications.• Profibus link has been tested successfully as well.• Integration and tests with PLC were done by M. Zaera in

Valencia.• A first version is installed at ITER since October for the HTS

current leads tests. This will serve as a real test of the devices and architecture.

• PLC + 2 DL Interface Boxes configured with 1oo2 Logic.• It “survived” a Preliminary Design Review at ITER.

CERN


Outline

19



First prototype

Second prototype

Profinet

[11]

CERN


Second Prototype

20

Design is finished and we manufactured 5 units that are working and ready for use.

The analogue part and interfaces with discharge loop and clients remain mainly unchanged except for small tweaks.

The functionality it’s the same. It can work together with a first prototype.

Main difference is the use of Profinet instead of Profibus for monitoring. • A brand new chip, TPS-1 from Renesas is used to manage the Profinet stack.• As it’s Ethernet based: substitution of the frontal DB-9 connector for 2 RJ-45 ports.• Allows precise time stamping of 1ms or less. (to be tested yet)• Much easier and faster to implement from the PLC point of view.

4 devices will be taken to ITER next week and sent to the different clients for early testing of the interface.

CERN


Outline

21



First prototype

Second prototype

Profinet

[11]

CERN


Profinet

22

Profinet offers several advantages over Profibus:

Profibus DP Profinet IO

Transmission Tech. RS485-like Ind. Ethernet

Data Exchange Only by request Cyclical or request

Transfer Rate Max. 12 Mbit/s 100 Mbit/s full duplex

# of devices 126 (and complicated) Arbitrary

Other data (IT services) No Yes

Device description (gsd) Keyword based XML based

Data priority Same for every slave Configurable

Topology Star and tree Line, tree, ring

CERN


TPS-1

23

This brand new chip is in charge of the Profinet stack.

196 pins 1mm pitch BGA package + 2 Fast Ethernet ports.

Documentation has been quite a challenge (missing information).

A lot of emails exchanged with support and several surprises.

Frist time programming of the chip is tedious.

But then it works incredibly well.

Next Steps:

Try the Isochronous Real Time mode (to achieve 1 ms sync)

Test with a Siemens PLC and play around with this synchronization options.

CERN


End

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THANKS FOR YOUR ATTENTION!

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CERN TE-MPE Jonathan Búrdalo Gil MARCH 2013 OVERVIEW OF ITER USER INTERFACE BOX EDMS 1283934