TCS-U Vacuum Control System - University of Washington Plasma
Contents
1. Front Panel Composite Logic NOMINA Individual device hardware interface modules NI DNET Interface Interface M Logic Hardware Layer Layer Layer Figure 3 2 The layer division of the system 3 1 1 The Interface Layer The interface layer is the part of the program that the user sees and interacts with Any part of the program which is used to display information on the front panel or gather user input is part of the interface layer The Interface directory contains code which is part of or was used to build the interface layer It is divided into groups of VIs pumps gauges and valves Each of these subdirectories contains the display logic sub vi for the item as well as a VI called FrontPanel which is an example of how the interface will look on the top level FrontPanel The controls on the example FrontPanel are wired to the display logic so that the whole unit can be copied and pasted from the block diagram of the example to the block diagram of the main FrontPanel This approach was used to save time wiring as there is much duplication on the main FrontPanel 3 1 2 The Logic Layer The logic layer is the part of the program which contains the operational rules for the system Code in this layer takes signals from the interface layer and ensures that no rules are broken before the signal is passed to the hardware layer The Logic directory contains the code which is part of the logic layer Each2. t recommend the built in SCC 28 Python might have been better suited for the scale and requirements or the TCS U Vac uum Control System software because those languages offer greater design flexibility to an experienced programmer It is expected that the Vacuum Control System software will continue to be beneficial and essential during the operation of TCS U 29 BIBLIOGRAPHY 1 National Instruments Corporation Ni dnet programmer reference help May 2004 2 Rockwell Support Everything you need to know to use devicenet explicit messaging al most Knowledgebase record G16551 DeviceNet Basics of Explicit Messaging January 2002 w Western Reserve Controls Inc Exeter Road Akron OH 44306 WRC1 JDAxx xx SmantMuz Plus DeviceNetTM User s Manual document pub 17 0 rev 0 70 edition March 2000 http www wrcakron com Western Reserve Controls Inc Exeter Road Akron OH 44306 1782 JDC De viceNet Serial Gateway User s Manual document 25 0 rev 5 05 edition September 2003 http www wrcakron com 30 Appendix A TROUBLESHOOTING If a component of the system is not behaving as expected the first thing to do is to double check the logic to discover which rule is being broken and is not allowing the desired state to be set What follows is an itemized list of things to check for common problems that may arise A 1 Turbo Pumps A 1 1 TP1 If turbo pump one TP1 will not turn on make sure that e T
3. The program will then move to the third frame of the sequence The code in this frame gets references to the DeviceNet Interface and all DeviceNet Objects which were opened from the DNetHardware VI and closes them The next chapter will describe the various controls that are found on the Front Panel of the Vacuum Control System It will outline what each control is for and how to use it 14 Chapter 5 USING THE SYSTEM 5 1 System Start up When the system starts the hardware is initialized and normally all front panel controls are set to their default values If it is desired that the front panel controls not be set to their defaults the mode ring should be set to override before the system is started The mode ring is located in the lower right corner of the screen and is labeled Mode as seen in Figure 5 1 The main front panel is displayed Figure 5 1 showing a diagram of the TCS vacuum system and the status of the various system components From the front panel the user can control all of the components of the vacuum system 5 2 Controls There are several different types of controls on the panel Controls are items that the user clicks on to set the software state Each control is labeled to indicate the hardware it controls Setting the control state on the interface does not directly effect the hardware but instead sends a signal to the logic layer which determines what hardware states will be set The controls are place
4. s NI DNet interface 19 Chapter 6 DEVICENET The hardware is controlled through a National Instruments PCI DNET DeviceNet in terface card which acts as the Master for all of the slave hardware devices on the DeviceNet network The DeviceNet hardware devices are the physical devices attached to TCS U and constitute the physical layer of the vacuum system Reading and writing through the inter face card to the hardware is done via the NI DNET API a collection of VIs provided with the card by National Instruments 6 1 Hardware Configuration Once the hardware has been set up and connected with the DeviceNet cable the devices must be configured The MacID and baud rate for each device must be set for every device on the network this can usually be done via hardware switches on the device The baud rate should be the same for all devices and the MacID should be unique for each device Some devices will require further configuration before they are ready for use For exam ple a digital IO multiplexer must be configured as to which points are to be inputs and which are outputs Each device has its own parameters that can be set these parameters should be described in the documentation for each device Properties for a device can be set using the DNetAttribute VI in the tools directory once the MacID and baud rate have been configured To set a property for a specific device the ClassID InstanceID and AttributeID which comprise the De
5. A 27 Bibliography iia A ls A a fa he 29 Appendix A Troubleshooting 30 ASI Turbo Pumps a Mur ee cea en Sh Ee AR Felon Bese 30 A2 Cryo PUMPS Air BAM Res at ok a et Ae DE ee le 31 A 3 Thermal Couple Pressure Gauges 32 A 4 Capacitance Manometer Gauges 32 A 5 Main Chamber Ion Gauge 32 AiO Valves a naa en ee a de Se i ee ae Oe le 32 LIST OF FIGURES Figure Number Page 1 1 An overview of the vacuum system DeviceNet architecture 1 3 1 The directory structure of the system 6 3 2 The layer division of the system 7 A1 Program flow e da a Wd a tall ale 10 4 2 Front Panel Block Diagram Organization 11 5 1 The front panel after start up 15 5 2 a closed valve b open valve c valve set to open but not open d valve handle matan lb Bie Roe he Name ani da datant 16 5 3 Turbo Pump and Cryo Pump Controls 17 6 1 The DNetAttribute Interface 20 iii LIST OF TABLES Table Number 6 1 Important JDC configuration parameters lv GLOSSARY NI National Instruments NI DNET National Instruments Device Net Interface API TCS U The Translation Confinement and Sustainment Upgrade FRC Experiment VI Virtual Instrument SCC Source Code C
6. DeviceNet communication a DeviceNet capable device is used to bridge between the vacuum system components that require digital inputs and outputs or RS232 communication There is no doubt that the Vacuum Control System serves as a vital component to TCS U operation Having a central control console allows a single operator to easily manipulate and monitor the machine conditions while the built in logic greatly reduces the chances of inadvertently causing damage to the system The software also protects the machine from catastrophic failures should a component break and conditions change while no one is monitoring the system The choice of LabVIEW as the programming language to implement the software por tion of the vacuum system may not in hindsight have been the most ideal While it allows quick prototyping of interfaces and device communication it is not trivial to build arbitrary custom interfaces and for large projects special care is required to maintain code readabil ity Without manual routing of wires and careful thought about block diagram placement the code quickly becomes unreadable In addition LabVIEW s built in source code control functionality is lacking For instance it is not uncommon for the SCC to refuse to check in a change because it thinks the server has a newer version While LabVIEW has certainly been sufficient and the resulting software quite good another language such as C or even the NI engineers don
7. and open many devices for use the Easy IO Config Vl is used This VI configures the interface device opens any number of devices for use and calls the Operate DeviceNet Interface VI with the Start operation code The Vacuum Control System software uses the DNetHardware VI for all interaction with DeviceNet hardware The first time a call is made to DNetHardware VI it will call the Easy IO Config VI to initialize the DeviceNet network To make sure the card is initialized and ready for use before before the main loop begins and starts trying to control the hardware a call is made to the DNetHardware VI during program start up 6 2 2 Device Communication Once an IO Object has been opened for a device the Read DeviceNet IO and Write De viceNet IO VIs can be used to receive data from and send data to the device To facilitate communication the Convert From DeviceNet Read and Convert For DeviceNet Write VIs are used to convert between LabVIEW data types and the raw DeviceNet data sent and received over the network All of the hardware layer components of the Vacuum Control System software that write data to devices on the network must first convert it to DeviceNet data before passing it to the DNetHardware VI along with the index corresponding to the device to which the data should be sent 6 2 3 Shutdown When a LabVIEW program is finished using DeviceNet it is necessary to close all IO Objects as well as the interface car
8. for controlling the standby and boost functions of the pump There is also a coolant indicator which shows green when the cooling water is flowing and red when it is not Each pump also has a temperature reading which is shown in the box below the two button controls 5 2 5 Gauges Although there are several types of gauges attached to the TCS vacuum system all of the gauges work the same way There is box which displays the gauge reading When a gauge is turned off the box will be filled with black 5 2 6 Fill Pressure Controls There are numerical boxes above each of the gauges that measure pressure in the gas puff plenums which allow a desired pressure for the plenum to be entered If the valves behind the plenum are set to be open the system will attempt to raise the plenum pressure to the desired value by allowing the valves to open until the desired pressure is reached at which point they will close 5 2 7 The STOP button In the lower left corner is a button labeled STOP Pressing the stop button will cause the program to exit the main loop If the system is in Normal mode all controls will be set to their default state If the system is in Override mode the hardware will be left in its current state The hardware interface and all device 10 objects will then be closed and the program will terminate The next chapter contains information about DeviceNet and communication with De viceNet enabled devices through LabVIEW
9. or Override mode respectively except that all controls are disabled These modes are helpful if the user desires to monitor the system but wants to guard against any incidental changes In Disabled mode the background will turn gray In Disabled Override mode the background will be red 5 2 2 Valve Controls gt lt eK i a b c d Figure 5 2 a closed valve b open valve c valve set to open but not open d valve handle The TCS vacuum system has many valves which are controllable from the computer system Each controllable valve is represented by the valve symbol Figure 5 2 Clicking on the symbol will toggle the valve open or closed A closed valve is drawn in blue Figure 1Caution it is possible to cause serious damage to the system when the control rules are disregarded 17 5 2a while an open valve is drawn green Figure 5 2b The desired state of the valve is indicated by the small rectangular handle on the valve symbol Figure 5 2d If the valve is set by the operator to be in the closed state the handle will be to the right and drawn in blue If the valve is set to be in the open state the handle will be to the left and drawn drawn in green The rest of the valve symbol indicates the actual state of the valve If the actual valve state and the desired valve state do not match the discrepancy will be highlighted by a red box drawn around the valve symbol Figure 5 2c 5 2 8 Turbo Pump Con
10. the configuration parameters for a device have been set the device will maintain the configuration even if the DeviceNet network is powered off Provided no changes are made to the system design the configuration can be done once prior to running the vacuum control system software the first time Only the control system software needs be run at any subsequent time that the system is brought on line 6 2 DeviceNet through LabVIEW 6 2 1 Initialization The NI DNET API provides VIs for use in LabVIEW programs to communicate with the DeviceNet hardware through the PCI DNET card The first call must be to the Open DeviceNet Interface VI which configures and opens an NI DNET Interface Object it initializes the card for use in the LabVIEW program Once the interface is open various devices can be opened for communication The DNetAttribute VI used to configure the devices uses an Explicit Messaging Object however for normal IO operations such as the control system software performs an NI DNET 1 0 Object is what is needed The final step in initializing the system is a call to the Operate DeviceNet Interface VI with the Start operation code 2see 2 for a full description of DeviceNet paths 3path values are in hexadecimal OF is 15 in decimal 22 The above procedure works well for programs that only use one or two devices on the network but the Vacuum Control System controls many more devices In order to initialize the card
11. three frames the initialization the main loop and the cleanup phase as shown in Figure 4 2 and are executed in that order Figure 4 1 shows a more detailed illustration of the overall program flow including logic and hardware VI functionality 4 1 Initialization When the program starts all of the code in the first frame labeled Initialization in 4 2 is executed before entering the second frame the Main loop The initialization code performs three tasks The first task is to call the DNetHardware VI which ensures that the DeviceNet interface card is ready to use for device communication before starting the main loop The second task is a check of the mode ring to determine the operating mode to start in If the mode is anything other than override all controls on the Front Panel are set to their default states This ensures that when device communication starts the system will be put into a safe default configuration The third task is to create a hardware error queue Any time a hardware error occurs the hardware VI involved will obtain a reference to this queue and place a descriptive message in the queue The queue is monitored by the FrontPanel VI and will pop up a dialog to display any messages placed in the queue 10 Initialize Hardware Set All Controls to Default except in Override Mode Create Error Queue Initialization Collect Control States Check Logic except in Overrid
12. TCS U Vacuum Control System Bj rn Hansen A dissertation submitted in partial fulfillment of the requirements for the degree of Master of Science in Aeronautics and Astronautics University of Washington 2007 Program Authorized to Offer Degree Aeronautics amp Astronautics University of Washington Graduate School This is to certify that I have examined this copy of a master s thesis by Bjgrn Hansen and have found that it is complete and satisfactory in all respects and that any and all revisions required by the final examining committee have been made Committee Members Alan L Hoffman Thomas R Jarboe Date In presenting this thesis in partial fulfillment of the requirements for a master s degree at the University of Washington I agree that the Library shall make its copies freely available for inspection I further agree that extensive copying of this thesis is allowable only for scholarly purposes consistent with fair use as prescribed in the U S Copyright Law Any other reproduction for any purpose or by any means shall not be allowed without my written permission Signature Date University of Washington Abstract TCS U Vacuum Control System Bj rn Hansen Chair of the Supervisory Committee Professor Alan Hoffman Aeronautics and Astronautics Engineering This paper describes the design implementation and usage of the Vacuum Control Sys tem for the TCS U plasma experiment Insta
13. anometer Gauges Capacitance manometer gauges have no logic check hardware connections Note the gauges labeled CM2 CM3 and CM4 are not actually capacitance manometers but are pressure transducers and have no logic A 5 Main Chamber Ion Gauge If the main chamber ion gauge IG1 will not turn on check hardware connections A 6 Valves A 6 1 VI If valve one V1 will not open make sure that e The main chamber gauge IG1 is on and reading less than 100 mTorr OR Capacitance Manometer one CM1 is on and reading less than 100 mTorr e Valve sever V7 is closed e Valve twenty four V24 is open e Turbo pump one TP1 is on and up to speed A 6 2 V2 If valve two V2 will not open make sure that e All other valves connected directly to the main chamber V1 V3 V4 V5 V6 V7 and V61 are closed 33 e The main chamber ion gauge 1G1 is on with a reading greater than 100 mTorr e Thermal couple five TC5 is on with a reading less than the IG1 reading A 6 3 VS If valve three V3 will not open make sure that e The main chamber ion gauge 1G1 is on with a reading less than 100 mTorr OR Capacitance Manometer one CM1 is on and reading less than 100 mTorr e Turbo pump two TP2 is on and up to speed e Valve two V2 is closed A 6 4 V4 If valve four V4 will not open make sure that e The main chamber ion gauge 1G1 is on with a reading less than 5 mTorr OR Capacitance Manometer o
14. ced from the LabVIEW Convert for DeviceNet Write VI for a short string has the length as the first byte no transmit delimiter is needed nor is any extra computation of string length To send data a record number must be appended through the Convert for DeviceNet Write VI with no byte offset and then the string to transmit is added at a byte offset of one The format of the received data is similar to the transmitted data with the addition of an error byte which comes after the record number The third byte rather than the second is then the string length and the remaining bytes are the ASCII characters that were received from the serial device 26 Table 6 1 Important JDC configuration parameters Any valid ASCII character Carriage return Dpex 0 127 0 255 o o Serial Character Format Serial Baud Rate Receive Delimiter Receive Buffer Size Transmit Buffer Size 27 Chapter 7 CONCLUSION The Vacuum Control System for the TCS U experiment was developed to allow safe operation of the vacuum system components while providing an easy to use interface for the operator LabVIEW was used extensively in developing the interface and logic for the system The connection and communication between the software portion of the system and the hardware on the machine is accomplished using the DeviceNet protocol which many of the hardware devices support directly In cases where devices do not directly support
15. d This can be done by using the Close VI or the Easy IO Close VI After the main loop exits in the Vacuum Control System software the Easy IO Close VI is used to close all IO Objects and the DeviceNet interface card 6 3 6 3 1 23 Digital IO with the WRC1 JDA 48 1 Configuring IOs as inputs or outputs To configure the digital I O points for the JDA48 use the DNetAttribute VI located in the Tools folder Perform the following steps for the device you wish to configure 1 10 Set the DeviceMacID to the address of the desired device Press the button in the LabVIEW toolbar Select binary in the format selector Set the ClassID to 15 and the AttributelD to 1 Set the InstanceID to a value between 6 and 11 depending which IO points you wish to configure An InstancelD of 6 corresponds to digital IO points 0 7 7 corresponds to points 8 15 etc Press to see the current settings of the selected eight IO points The right most digit is the lowest For example if the InstancelD is six the right most digit corresponds to point 0 and the leftmost to point 7 If the setting was successfully retrieved from the device the Device Error box should display E Adjust the value next to to the desired IO point settings and press to send the settings to the device Make sure the AttrDataLength field is set to 1 If the operation was successful the DeviceError should display 10 Pre
16. d over a schematic diagram of the TCS vacuum system to give a better indication of the relationship between individual controls 5 2 1 Mode selector In the lower right corner of the screen there is a button which allows the user to switch between modes The default mode is Normal Other modes are Override Disabled and Override Disabled A password is required in order to change modes If the password is correctly entered and the user clicks the button the system is put into the desired mode If the password is incorrect or the user clicks the button the system remains 15 vss NZ NZ vs Ceramic va ZE ZS 2 Break a ce i M Puff Pressure Relief nn Einin Ti E 001000009990 i i KR iE a a a E a N E a AT cizgi nant Bit HUG v8 Puy T M A Ses y 3 3 An s f mlz 2 y S 018 Z a MIE 3 8 2 E a E a z z El iS 4 5 g 3 E A Fi 3 Ne 2 y Pressure Relief M 7 M 10 3 _ Solenoid ae M Valves Cie is Ground Zone 3 Ground Zone 2 Ground Zone Ground Zone 0 EA eoc tog Siop Enabled Tempers Log intervalia o Sa jo Figure 5 1 The front panel after start up in the current mode The password dialog will time out after ten seconds in which case the system will remain in the current state Normal mode allows the user to set controls on the front panel any way the operator would like but this will not change the state of the hardwar
17. e Mode Main Set Hardware States Get Hardware States Set Indicator States if stop pressed Set All Controls to Default except in Override Mode a ANUP Check Stop Button Check for Mode Change Prompt for Password if Mode Change Check Error Queue if stop pressed Close Hardware Interfaces Figure 4 1 Program flow 4 2 The Main Loop 4 2 1 FrontPanel code After initialization is complete the program enters the second frame labeled Main Loop in 4 2 which contains four while loops which run in parallel The while loops run until the button is pressed The upper loop has two tasks First it checks if the stop button has been pressed If it has appropriate action depending on the current mode of the system is taken to prepare for system shutdown Second the loop checks for changes in the mode ring control If the user has attempted to change the mode a password prompt 11 Initialization Main Loop Clean Up Check for Stop Close DNet card Check for Mode Change Open DNet card Initialize Controls Temperature Logging Check Controls Set up Error Queue Run Logic Update Indicators Display Errors Figure 4 2 Front Panel Block Diagram Organization is displayed Only if a correct password is supplied is any mode change actually effected The small lower left loop labeled Display Errors in Figure 4 2 checks the error queue for errors and displays a dialog s
18. e the necessary information The third parameter in Table 6 1 the receive delimiter is the ASCII character which the ASCII device will send as the terminating character in each message The JDC will not transmit any received characters over the DeviceNet network until either the delimiter character is received or the receive buffer overflows The size of the buffer is controlled by the fourth parameter in the table the received buffer size class 15 instance 5 attribute 1 which is the maximum number of characters that the JDC expects to receive from the ASCII device The last parameter the transmit buffer size is similar to the receive buffer size but applies to transmitted characters 6 4 2 Sending and Receiving Data There are two methods to send ASCII data over DeviceNet to the JDC In both cases the first byte of the data is the record number The JDC only sends ASCII to the serial device 25 once each time the record number is changed The second byte of the data sent to the JDC is the length of the ASCII string to transmit or zero The remaining bytes are the ASCII characters The difference between the two methods is that if the string length byte is zero the JDC will transmit all of the consecutive bytes up to and including the character which has been set as the transmit delimiter If the string length is non zero the JDC will send exactly that number of bytes regardless of what the characters are Since the byte array produ
19. e unless the logic conditions are met If the user sets a control to a state there will be a visual indication as to whether the hardware actually changes to that state or not In Normal mode if the system can not be put into the desired state because some rule is violated the user may choose to leave the control set in the desired state and the hardware will automatically be put into the desired state as soon as it would not violate any rules The user may have to refer to the control 16 logic rules Appendix A to determine the reason a desired setting is disallowed When the system is in Normal mode the background will be blue A second mode option is the Override mode Override mode is much like normal mode except that the control logic is bypassed so the hardware is put in whatever state the user sets When Override mode is requested all controls are immediately set to the current hardware state so that the act of changing to Override mode will not in itself cause any changes This is a safeguard against unintended changes to the hardware When the system returns from Override mode the control rules immediately come back into effect so any hardware state that was in violation of the control rules is put back into compliance When the system is in Override mode the background will be red The third and fourth modes available are Disabled and Disabled Override In Disabled or Disabled Override mode the system runs the same as in Normal
20. he cooling water light WC is green e Scroll Pump 1 is ON and Valve 22 V22 is open OR Scroll Pump 2 is ON e Valve 12 V12 is open e Thermal couple five TC5 is on the gauge symbol is green and has a pressure reading less than 1000 mTorr A 1 2 TP2 If turbo pump two TP2 will not turn on make sure that e The cooling water light WC is green e Valve 13 V13 is open 31 e Thermal couple five TC5 is on the gauge symbol is green and has a pressure reading less than 1000 mTorr A 1 3 TP5 If turbo pump five TP5 will not turn on make sure that e The cooling water light WC is green e Valve 16 V16 is open e Thermal couple six TC6 is on the gauge symbol is green and has a pressure reading less than 1000 mTorr A 2 Cryo Pumps A 2 1 CP1 If cryo pump one CP1 will not turn on make sure that e The cooling water light WC is green Cryo pump one CP1 can skip its cooldown cycle if e Valve 25 V25 is closed e Cryo pump one CP1 has a temperature less than 20K A 2 2 CP2 If cryo pump two CP2 will not turn on make sure that e The cooling water light WC is green Cryo pump one CP1 can skip its cooldown cycle if e Valve 26 V26 is closed e Cryo pump two CP2 has a temperature less than 20K 32 A 3 Thermal Couple Pressure Gauges Thermocouple gauges have no logic so if there is a problem it is most likely hardware related Check all connections A 4 Capacitance M
21. hould any hardware errors occur The other small loop on the left of the frame labeled Temperature Logging in Fig ure 4 2 checks to see if temperature logging is enabled and if so writes the current temperature of all thermocouples on TCS U to a spreadsheet file on the desktop called TCSU_TemperatureLog xls The large loop in the lower right labeled Check Controls Run Logic Update Indicators in Figure 4 2 contains two structures a Stacked Sequence and a Case Structure The Stacked Sequence was employed mainly for block diagram readability and to keep the wiring task manageable The first frame in the sequence reads the values of the thermo couples on TCS U and updates the indicators on the front panel It also passes the values to the heater control logic instead of passing through CompositeLogic because the heater 12 control is independent of the vacuum system control The remaining frames in the sequence gather values from all of the controls on the front panel and update the indicators with values determined during the previous loop execution Once all frames have been executed the program passes the control state values to the CompositeLogic VI 4 2 2 CompositeLogic Since there are many control states used in the system logic individual control outputs are bundled into clusters before being passed to the CompositeLogic VI The clusters are then unbundled inside the CompositeLogic VI before being passed to the individual
22. ing the vacuum system Chapter 6 is a description of various DeviceNet hardware how it is configured and how it interfaces with LabVIEW Chapter 7 contains some conclusions and recommendations on how a similar system could be developed Chapter 2 INSTALLATION 2 1 The Development Environment In order to set up a development environment on a new machine the LabVIEW development environment must be installed If the program will also be run on the same machine e g for testing an NI DeviceNet Master card must also be installed on the machine After installing LabVIEW and the DeviceNet Master card the NI D NET drivers must also be installed these should be downloaded from the NI website rather than using the drivers provided on the CD that came with the card as the drivers provided on the CD are older and do not work correctly After installing the hardware and software mentioned above the following steps should be taken Map terrance public to drive X Open LabVIEW Click Tools Source Code Control Configure SCC Options Select built in e Set master directory to X Bjorn LabViewSCC Click e Set the local work directory to C VacuumControl these steps assume the SCC repository is located on the terrance public share in the Bjorn LabViewSCC directory Select windows NT 2000 XP Click Click again e Click Tools Source Code Control Launch SCC Provider Select Project Vacuum Control System F
23. llation of the required software for system development is also described as is configuration of hardware controlled by the system TABLE OF CONTENTS Page List Of Fiouress a mas dan ek AS de Et BO a Me BASS te a iii List of Tables a saos ed ad e eis ee Mendes De ek ds de guet iv Glossary sok ga E a e A a a A A A AA A eed v Chapter 1 Introduction 20 ei eve ue e nce AE A gaie 1 Chapter 2 Mistall tion s 42 2 n a uns ee p en ea M ee 3 2 1 The Development Environment 3 2 2 Building an Executable 4 Chapter 3 Program Overview 6 3 1 Code and Directory Structure 6 Chapter 4 Program Execution 9 4 1 Initialization 424 Bud ek das he AU ae ae La dd a a S 9 42 The Main Loop eo a oa Aa den eke due moe a due EAU UE e 10 AS Clean Up 41 e ER ee Be Steven eae A Mr ss 13 Chapter 5 Using the system 444 44e eur w he Bb me dial o e aih 14 Dal System otat Up asii E UMR dant Du dt es eR aS 14 D 2 Controls nc ns e A Br a A de ter nl 14 Chapter 6 DeviceNet iniciada ae take Ske AE e ag SAP D 19 6 1 Hardware Configuration 19 6 2 DeviceNet through LabVIEW 21 6 8 Digital IO with the WRC1 JDA 48 1 eh ee Sed el Bs net es doive 23 6 4 RS232 through a 1782 JDC 24 Chapter 7 CONCIUSION AA Seah me CE Mie Eel ei A a ee
24. logic VIs The CompositeLogic VI employs a stacked sequence structure as well again for read ability and wiring management reasons The outputs of many of the subVIs used in the CompositeLogic VI are used as inputs to many of the other logic sub VIs These outputs are often wired to an indicator so that they can be read from a local variable rather than through direct wiring which would result in an unmanageable mess of wires The output signal from each logic VI is passed to the hardware VI for the DeviceNet device that the component is attached to The outputs from the hardware VIs are often wired to indicators for use as inputs to the logic VIs and are also bundled into cluster that are the outputs of the CompositeLogic VI 4 2 3 Hardware VIs The hardware VIs for each device take the input signal and convert it to DeviceNet Data which is passed to the correct device through the DNetHardware VI The DNetHardware keeps an array of Device Object Handles so the device index passed to the DnetHardware VI selects which device the data will be sent to 13 4 3 Clean Up When the stop button is pressed on the FrontPanel the top while loop will display a confirmation dialog to confirm that the system should be shut down When the user confirms presses OK that the system should be shut down if the system is in normal mode the loop will set all controls to default The loop will then exit The lower loops will then stop as well
25. ne CM1 is on and reading less than 5 mTorr e Cryo pump one CP1 is on and has a temperature less than 13K e Valve 25 V25 is closed A 6 5 V5 If valve five V5 will not open make sure that e The main chamber ion gauge IG1 is on with a reading less than 5 mTorr OR Capacitance Manometer one CM1 is on and reading less than 5 mTorr 34 e Cryo pump two CP2 is on and has a temperature less than 13K e Valve 26 V26 is closed A 6 6 V6 If valve six V6 will not open make sure that e The main chamber ion gauge IG1 is on with a reading less than 100 mTorr OR Capacitance Manometer one CM1 is on and reading less than 100 mTorr e Turbo pump five TP5 is on and up to speed A 6 7 V7 If valve seven V7 will not open make sure that e The main chamber ion gauge IG1 is on with a reading less than 5 mTorr OR Capacitance Manometer one CM1 is on and reading less than 5 mTorr A 6 8 V25 e Valve four V4 is closed A 6 9 V26 e Valve five V5 is closed A 6 10 V52 v56 If any of these valves will not open check that the pressure reading in the plenum to which they are connected is less than the desired pressure set in the box just above the reading A 6 11 V61 If valve 61 V61 will not open make sure that e The valves V1 V2 V3 V4 V5 V6 V7 and V62 are closed 39
26. ontrol 0 0 1 Conventions The following conventions have been used throughout the document file or directory names VI names button text ACKNOWLEDGMENTS The author wishes to express sincere appreciation to the scientists and technicians at the Redmond Plasma Physics Laboratory for their help and feedback in designing the Vacuum Control System vi Chapter 1 INTRODUCTION The vacuum system on TCS U is controlled from a computer running a LabVIEW program which allows the operator to perform various control tasks through a graphical interface The Vacuum Control System software ensures that safety rules are not violated which prevents conditions which might cause damage to system components There is also an override mode which allows the operator to disregard the safety logic if necessary The software communicates with the hardware over a DeviceNet network All network communication is done through a National Instruments PCI DeviceNet scanner card which is installed in the PC on which the software runs Figure 1 1 An overview of the vacuum system DeviceNet architecture Chapter 2 describes the steps involved in setting up a development environment and how to build the final executable In chapter 3 an overview of the code structure of the Vacuum Control System is given Chapter 4 takes a step by step look at how the code executes and outlines the program flow Chapter 5 illustrate how the system is used by the person operat
27. piece of hardware that has logical conditions which determine the hardware s allowed state has a VI in the Logic directory which implements the control rules for that hardware component There is also a Composite Logic VI which ties all of the individual pieces together The Composite Logic VI ties the logic layer to the interface and hardware layers 3 1 3 The hardware Layer The Hardware directory contains VIs which serve as interfaces for the actual hardware de vices attached to the system There is a separate VI for every DeviceNet device All of these hardware VIs send and receive data to and from the hardware through the DNetHardware VI To facilitate development and testing of the system before the actual hardware was in place the actual calls to the hardware operations in each subVI were enclosed in a case statement which allowed easy switching between simulated hardware and real hardware This proved to be an effective way to test some functionality of the program while the real hardware was not yet in place In the next chapter I will step through the execution sequence of the code and identify the important parts for understanding the program design and flow Chapter 4 PROGRAM EXECUTION The program is run by starting the FrontPanel VI All other VIs are called from within FrontPanel or as subVIs of those called from FrontPanel The FrontPanel VI uses a Flat Sequence as its outermost structure which divides the program into
28. pment version of the Vacuum Control System can be run from within LabVIEW for testing purposes after shutting down the executable version the new executable should only be built when changes are complete and have been tested In the next chapter I will discuss the code and directory structure of the Vacuum Control System software Chapter 3 PROGRAM OVERVIEW 3 1 Code and Directory Structure The program is divided into three layers an interface layer a logic layer and a hardware layer as shown in Figure 3 2 The VIs have been organized into directories according to this scheme shown in Figure 3 1 The exception is that the top level VI FrontPanel vi is in the top level directory This makes it quick to locate which is useful since it is the VI that is actually run This is further discussed in Chapter 4 There is also a utility directory which contains utility functions used by the Front Panel and also contains Globals vi the global variables used by the program The tools directory contains VIs which were created to assist in setting up or maintaining the system but are not directly part of the control system software The Test directory contains VIs used to test individual devices independent of the main program The Documentation directory contains the documentation for the system Vafuum_syste Hardware Logic Interface FrontPanel vi Tools Documentation Utility Test Figure 3 1 The directory structure of the system
29. rontPanel vi e Click Selections Select Changed files e Click File Get Latest Version e Close the window You should now have a newly checked out copy of the latest version of the Vacuum Control System In order to edit any of the VIs in the program you should open the VI click Tools Source Code Control Check Out After making changes check your changes in by clicking on Tools Source Code Control Check In 2 2 Building an Executable When improvements have been made to the Vacuum Control program a new executable should be built to replace the one that is normally running and controlling the system This is very easy to do once it is set up Simply open LabVIEW and select Tools Build Application or Shared Library DLL Load the build script from C VacuumControlExe VacuumControlSystemBuildScript bld If the build script does not exist it can be created in the LabVIEW dialog by choosing appropriate parameters such as the executable name and output directory and then saving the build script Once the build script is loaded click the button LabVIEW may ask to close some VIs if there are any open and ask for confirmation on replacing the old VacuumControl exe executable It will then build the new executable It is recommended that the running VacuumControl exe program be shut down prior to pressing the build button After building the new executable it can be run to start the newly upgraded system Note that the develo
30. ss to verify the new settings have taken effect Change the InstancelD to the next value if more points need to be configured and GET SET those parameters as well When all configuration for this device is complete press Stop For more details on configurable parameters for the JDA 48 see 3 24 6 4 RS232 through a 1782 JDC The 1782 JDC is a family of DeviceNet to serial link communication gateways that allow communication with ASCII devices over a DeviceNet network The JDC allows communi cation with either RS232 or RS485 devices 4 The JDC has a five terminal connector for connecting to the DeviceNet network and a three terminal connector for interfacing with the ASCII serial device it will be connected to The serial terminals are RX receive TX transmit and GND ground There is also a set of hardware switches that allow the DeviceNet address to be set 6 4 1 Configuring the JDC The JDC has several parameters which must be set correctly in order to communicate with a given ASCII device These are given in Table 6 1 For a list of other parameters which can be configured for the JDC see the reference manual for the device 4 The first parameter in Table 6 1 the serial character format class 15 instance 1 at tribute 1 as well as the baud rate class 15 instance 1 attribute 1 must match the format and baud rate of the ASCII device the JDC will connect to The documentation for the ASCII device should giv
31. trols Each turbo pump control has a button for activating the pump as well as coolant and speed indicators Figure 5 3 If the pump is currently off the button will be blue with the word in white lettering When the pump is on the button will be green with the word in white lettering The lettering indicates the desired state of the pump and the color gives an indication of the status If the button turns red it means that the desired state of the pump does not match the actual pump state So if the button is says ON but is red then the pump is set to be on but is not actually running for some reason The small light labeled WC is the cooling water indicator It will be green if the cooling water is flowing and red otherwise The last indicator for a turbo pump is the speed box It displays the current speed in RPM of the pump This is useful to know because the pump button color will not indicate that the pump is actually on until it is up to speed Standby Boost 5 d Ol oO fal dansi Cooling 5 Water Temperature Bw a 1305 CP2 Figure 5 3 Turbo Pump and Cryo Pump Controls 18 5 2 4 Cryo Pump Controls The two cryo pumps controls are similar to the turbo pump controls Figure 5 3 The cryos are considered to be always on and will only be actively shut off by the control system if they lose cooling water flow thus there is no ON OFF button on the front panel Each Pump control does however have two buttons
32. viceNet path for the property must be entered in the corresponding fields in the DNetAttribute VI The value of the property can then be read from or written to the device using the and buttons respectively The DeviceNet path for the property may be obtained from the device documentation or it can be deduced by reading the devices on the TCS U DeviceNet network are all set to 125 kbps 20 Figure 6 1 The DNetAttribute Interface the eds file that came with the device As an example consider the WRC1 JDA 48 1 device which is a multiplexer with up to 48 discreet IO points Each point can be configured as either an input or an output There are six banks of eight points Each bank can be configured by setting the correct property to a value represented by single byte eight bits one bit for each IO point The following entry taken from the eds file for the WRC1 JDA 48 1 contains the information for the parameter used to configure the discreet IO points in bank 1 of the device Param7 0 6 20 OF 24 7 30 1 class 15 inst 7 att 1 0x0 24 1 1 byte int DIO Bank 1 wee gt 21 Check box to enable as discrete output 0 0xff 0 The string 20 OF 24 7 30 1 gives the path to the device class OF instance 7 attribute 1 By setting the appropriate value for class 15 instance 7 attribute 1 with the DNetAttribute program each of the IO points in bank 1 can be configured as an input or an output Once
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