Real-time Controller User Manual
Contents
1. Ethernet I 9 45V 3 3V 2 5V 1 2V m f d Mode O A N E b pv I ee 7 T 3 KOySWIEGR de 24V logic WE C e LED 2 2 X Output Relay Enable Enabled Interlock 24VDC in Figure 6 A560 circuit architecture A560 User Manual A560 UM 150413 Page 20 of 67 PSI System Controls and Diagnostics The main board mounts the A60 card and carries the fiber optic transmitters and receivers for the first five loops the power conditioning components status LEDs reset switch and jumper banks for build time option selection Redundant CPLDs handle watchdog functions and interlock functions including sensing the state of the diagnostic mode keyswitch Fiber optic transmitters and receivers for loops 6 to 10 are mounted on a mezzanine PCB The front panel keyswitch is read by the CPLD Its primary purpose is to allow the device to operate in a service or diagnostic mode where some errors are ignored A typical use is to allow maps sequences of output states on connected devices and the resulting input states to run without tolerance checks being applied to the inputs The gate input accepts a TTL level signal that can be used to synchronize actions performed by the A560 to external events The gate out connectors echoes the gate inputs with very low latency allowing multiple devices to be connected in a daisy chain con2. ccccccrsssssccccccssssssssccccccscssssscsscccssssssssccccooes 39 Example analog voltage waveforms produced by map execution sssscccccccsssssssccccccscccssssscccooes 40 Display during map execution eR 40 Simple example network for EPICS communications ssseeeeoesssseeecocsssesececossssecocossssececoossssscesossssssee 42 Example xml system configuration file for EPICS sseseecoossssseccocssssscceccssssscecocsssssceecssssssececssssssseesoo 44 Example power supply user control created using CS Studio BOY eere 45 Normal power Up LED Sequeira uae eT bares 49 LED sequence if the bootloader detects an error ecce ecce eee ee eee eee eee eese s eee etes eooss 54 POW ECO A EOI eq E EE eI REV EU E 55 USB Blaster and JTAG adaptor osoena Iran Ves EEEXa E Ci S esa Ea Sa OS TON CN Ne 58 A60 processor board showing programming connector location eee e eee e eee e eere eene enun 59 Programmer Connection 59 Quartus programming software SCLEEN cccccccrrssssccccccccsssssscsccccsccssssscscccscccssssscccccssessssssccccsssesesscess 60 Fam Otel Temo Valonia ia 61 Fan power connector 2 pin Mol dd 62 A560_UM_150413 Page 5 of 67 PSI System Controls and Diagnostics 3 Safety Information This unit is designed for compliance with harmonized electrical safety standard EN6
3. Remove the four M2 5 screws holding the A560 top cover down slide it back to disengage from the front panel and lift it clear 5 Locate the A60 processor card which mounts the Ethernet connector 6 Locate the small 2x5 header on the A60 board A560 User Manual A560 UM 150413 Page 58 of 67 PSI System Controls and Diagnostics gt T WW iti QT LU rn codi EEE FEN go Figure 33 A60 processor board showing programming connector location 7 Very carefully connect the adapter to the header such that the cable is coming out toward the back panel as shown in the figure below Take care that the connector is not offset on the board header Do not pull on the USB Blaster once the connection is made Figure 34 Programmer connection A560 User Manual A560 UM 150413 Page 59 of 67 PSI System Controls and Diagnostics 8 Install the Altera Quartus programmer if necessary and connect the USB cable to the computer 9 Open the Quartus software 10 In Hardware Setup select the USB Blaster If it 15 not present then the USB driver did not install correctly 11 Select File gt Open and open A60 cdf The screen should now resemble the figure below The figure shows a connection via an EthernetBlaster rather than a USBBlaster but other displays will be the same Wl Programmer C Work Boards AS60 FPGA Trunk A60 Flash Debug A60 A60 A60 Fpga A60_Bootloader ToFlint A60 cdf on LE
4. o 0 oo 16 MessageNoUndestod 15 DataNotinitialized ss 1 StatusError o o 9 Mo onConmllerBmor ss 8 Mo onConroleCommsEror 6 InvaidVersion Firmware version is incompatible o o 5 OA ooo ooo Error on fiber optic loop characters not echoing correctly CA 0 00 0o EON NO ss None No error 115 UnexpectedNumberOfParameters 120 NumericDataBrror 121 TnvalidcharacterInNumber 200 NotConnected o 221 SettingConflict oo A560 User Manual A560 UM 150413 Page 52 of 67 PSI System Controls and Diagnostics 222 DataOutOfRange 224 llegalPaameterVale HardwareError A 241 HardwareMissing TxRamFailure AAA 243 RxRamPalue 244 FmRamPalue 255 CorruptMedia Pt 291 OuOfMemoy o o DeviceBusy A 335 ProgamNolLoaded ss QueueOverflow AAA 401 DataNotAvailable oo 901 jJOveflow S ooo 902 Timeut Jo 000 903 Address 904 Msglrengh 0 ooo DeviceTypeConflict Checksum ANN 907 ProgramNotFound 908 FlashError 0000 ooo StateConflict ss EEUUVUO O i BENE A Oo O D i A560 User Manual A560 UM 150413 Page 53 of 67 PSI System Controls and Diagnostics 20 Using the A60 Recovery Utility If the A560 firmware becomes corrupted you may not be able to connect to the device with the PTC DiagnosticG2 In this case you can use the A60 recovery utility to reload the firmware provided that the boot loader code
5. Automatically transition straight to done so that each DAC value is set for one time slice gt state name initializing test success ddone Zarqument gt 0 lt arqument gt lt target gt 0 lt target gt z test lt state gt lt state name working gt state name done gt channel name c m 1 aoutl source map dac X Pie channel name c mi0 1 aout source map dac Y gt state lt fprocess gt z prnoeesses z system Figure 23 xml file example for real time processing continued The map format is a simple list of ASCII coded numbers for example a csv file In the example the first analog voltage 1s used to generate a triangle waveform the second analog voltage a triangle waveform with five times higher frequency A digital bit is set when the map is running 0 0 0 1 0 5 0 2 1 0 3 1 5 0 4 2 0 5 2 5 0 6 3 Gs BEC 0 3 1 5 0 2 1 0 1 0 5 0 0 0 0 To run the map first load the configuration xml file Pesdcefeweten The message area will report if 1t was able to read the file correctly Note that the system area tree will now A560 User Manual A560 UM 150413 Page 39 of 67 PSI System Controls and Diagnostics show the system configuration as you specified it in the file which overrides any discovered Upload Map configuration Next load the map file Finally arm and initiate to execute the map cms inae Map MM Pos 200 05 SAVE REC Action Save Image Fi
6. COMMUNICATION TO THE HOST COMPUTER 5 ierit csudes teen serlo gutes dd de Eee INTE 2l 10 2 COMMUNICATION TO SLAVE DEVICES 0ccscsccscascscaccecsccscsccsesceccscscscascscasescesescssescssescssescesascscaseecasesceseecs 21 10 3 EMBEDDED SOFTWARE art a ee Or pesce rof 22 11 GETTING STARTED USING THE PTC DIAGNOSTIC G2 HOST PROGRAM ee ee eee eee eene enne 23 11 1 INSTALLATION diciones de OE eT 23 11 2 CONNECTING TO THE ADO ra os tn desd 24 11 3 SCREEN AX O O do ad e dao de dnd Ea 29 11 4 PROPERTIES a e Eo atea Decr atn pets E aca per e eo a eta 30 11 4 1 ETT TECLA al us 30 11 4 2 CHAN CIN STINE TIRAS Si cod 31 11 4 3 Restor the dejan IF Adri 32 12 USING THE A560 ON A NETWORK esesesecscscsesesesesececeseocococoscseseseseseseseseseososcsoseseseseseseseseseseoscscseseseseseses 33 12 1 NETWORK CONFIGURATIONS 3528852850 alu ed Passo sotepe a EDUC AMA CLR E CRUS DU Ae c EID ORE ei 33 12 2 FRENAT SUundL i Ibr EN TI I LI EI DD RE TAS RE LN e ft eae 35 I3 ERONT PANELEECDLIE a ode loei eens ie esos dic ce eee e ets es edicere m 36 13 1 FIEM WARE 0 6 161 39 AND EAREIEB 43 2 2 ees petet oe er Recens ee ala Id 36 13 2 IENHANCED DISPEA Vda leas de sudeste Deoa de Dd telas sine 36 A560 User Manual A560 UM 150413 Page 2 of 67 PSI System Controls and Diagnostics 14 REAL TIME PROCESSING dos 37 14 1 SETTING UP REALTIME PROCESSENG e d ed DUE 37 15 CONNECIING DEVICES USING ERIC S cian dosis 42 15 1 MUEDOTUIS DS feft ELE EU AM IA rM
7. DiagnosticG2 program which loop controllers are involved just an A560 at IP 192 168 1 86 in this example The timeslice parameter is the time in usec for each step in the map The devices connected by the loop controller that will set outputs and read inputs are listed just one M10 device with address 1 on loop 5 in this example Specific local names are defined for the particular M10 T O points that will be used A560 User Manual A560 UM 150413 Page 37 of 67 PSI System Controls and Diagnostics x xml version 1 0 encoding iso 8859 1 SYS Tem xmlns http www ptcusa caom xmlns xsi http wmmr w3 org 7001 XMLschema instance xsi schemaLocation http vwww ptceusa com A510 xsd gt lt map gt l The map contains the DAC points for the profile gt lt channel name map dac X type analog gt lt channel name map dac Y type analog gt lt map gt cloopeontreollers gt lt loopeontroller type A560 name A560 1 ip 192 168 1 86 timeout 50 timeslice 100000 gt Loops lt Al LOOPS okockokokockokokokok kok ko ko ko oko ko ko ko kocko koko ko EEE EEE ko ko k EEE k ko ok EEE EEE kb ck ok k kk ko kk kk kk kk dk ck ko ko kb ko EEE EEE EEE EEE L lt loop number 5 name A560 1 loop 3 gt zhoards board type M10 name m10 1 address 1 gt 2channels gt channel name r m 1 aini wire analog in 1 gt channel name r m10 1 ain wire analog in 2 channel name e m0
8. Subscribe techniques to communicate between the various computers Most servers called Input Output Controllers or IOCs perform real world I O and local control tasks and publish this information to clients using the Channel Access CA network protocol CA 1s specially designed for the kind of high bandwidth soft real time networking applications that EPICS is used for and is one reason why it can be used to build a control system comprising hundreds of computers Pyramid supplies an executable called IG2 which embeds an open source Channel Access Server from the EPICS community This allows connection to front end devices using the A560 via the Ethernet interface IG2 is configured for the devices you wish to connect using editable xml files Once IG2 1s running on a computer in your network then any other computer can run a client program which can display and control the process variables for the devices In the simple network in figure below the process variables of an M10 attached to the A560 via fiber optics are exposed to the network by the IG2 service running on a server computer The M10 might typically be interfacing a power supply One or more client computers can then access the values GUI client IG2 server Router Switch Figure 26 Simple example network for EPICS communications A560 User Manual A560 UM 150413 Page 42 of 67 PSI System Controls and Diagnostics There is a wide range of client interfaces from t
9. The release date of a Pyramid Technical Consultants Inc user manual can be determined from the document file name where it is encoded yymmdd For example B1I0_UM_080105 would be a B10 manual released on 5 January 2008 A560_UM_150413 First general release A560 User Manual A560 UM 150413 Page 67 of 67
10. Windows XP Vista Windows 7 and Windows 8 The PC must have a standard Ethernet port A Linux distribution 1s also available on request Contact Pyramid Technical Consultants to get the necessary files and installation instructions Run the installer and follow the prompts On Windows 7 systems you will be asked to allow the installer to make changes to the computer after the confirmation stage You will require administrator access to permit this A560 User Manual A560 UM_ 150413 Page 23 of 67 PSI System Controls and Diagnostics Select Installation Folder ramo f Technical Consukants Inc The installer will quide you through the steps required to install PTCDiagnosticG2 on your computer The installer will install PTCDiagnosticG to the following folder To install in this folder click Next To install to a different folder enter it below or click Browse Folder CAProgram Files Pyramid Technical Consultants Inc PTCDiagnostic Browse Disk Cost Install PTCDiagnosticG2 for yourself orfor anyone who uses this computer WARNING This computer program is protected by copyright law and international treaties Unauthorized duplication or distribution of this program or any portion of it may result in severe civil or criminal penalties and will be prosecuted to the maximum extent possible under the law 2 9 Everyone Just me Installing PT CDiagnosticG2 y b T
11. be eae ER EI 42 15 2 INSTALLING AND CONFIGURING G2 iia orina 43 16 CONNECTORS rora a E E T ande 46 16 1 REARPANELCONNECTORS aora A ENEN 46 16 1 1 ETRE rNEECOMMUNICO ION i 46 16 1 2 ERAS TAS POD AS M M 46 16 1 3 TUE OCK DIT de d 46 16 1 4 Relay POTASA lada toledo OS 46 16 1 5 CAES NA Ec RES 46 16 1 6 EEN os ea on o A E 46 16 1 7 F OFOP LOOP DOR aa 47 16 1 8 ELEVE DOWER VINO EORR cc c ile ia ni ici 47 16 1 9 GTO A NUS lt A A A aos 47 I7 CONTROLS AANDINDICATONRS our atac 48 17 1 FRONT PANEL CONTROLS tamara A dE a ep eL A paE ILS Rc Leu D DeL ieee 48 17 1 1 NS A O 48 17 1 2 A A tentescusd optet p tEU Pa do ikdour Sete 46 172 REARJDANBECONIBOLDS2 2 2 c 5 mede mci Mensis Mr Ii I ie Dl UI Pi M DM Ii nie A DA D Da ENTE 48 17 21 AA IO A RR MARRE NES 48 17 3 DEONTPANEICINDICATORS 5 dte risdettavdcnto esten cadant nd cer creduto cete rode di eo cp Lese IE E 48 17 3 1 JU QD ME 48 17 3 2 POWER TIA 6121 O E EA 48 17 3 3 RK CVS WICH Ote INICIA SAA A 48 17 4 REARPANEE INDICA TOR Stilo ET RETA 48 17 4 1 A M PRETIO A AAT 48 17 4 2 JACITVO O E NN 49 17 4 3 ECN MESRINE ERR RE 49 17 4 4 AAA PI ota eles T NE EOE 49 17 4 5 FON FUNS OUO O E E E Oise easly bites tucexsr tests tt 49 17 4 6 RIA Sa COTOS id TP 49 TS HAUT PoP ENDING od cines 50 19 ERROR CODES ot li 52 20 USING THE AGO RECOVERY UTIL Tin cias 54 20 1 DETERMINING THAT THE BOOTLOADER IS INTACT BUT THE APPLICATION CODE MEMORY IS CORRUPT 54 20 2 REZLOADING THE FIRMWARE in
12. below shows an A560 interfacing some Pyramid devices which in its turn could be controlling power supplies motors or actuators or reading current magnetic field and so on The A560 has ten loop ports each capable of connecting up to fifteen devices The slave devices are locally powered Each device can have a large number of I O points a large scale system can be built up even with a single A560 The schematic example in figure 4 shows four looped remote devices on the first fiber optic loop port and three on the second loop port The A560 is connected via a switch on a local area network to a host computer The fibers can be very long up to several hundred meters if good quality silica fiber is used The data is completely immune to electrical interference and the fibers can cross high voltage gaps without problem so you can control clusters of equipment in high voltage terminals Slave Slave Slave Slave device device device device E E L1 ESI m pun DD DD Slave mfg device MF Slave jm inm device DZ me Fiber optic communication loops Slave A560 device Figure 4 Connecting multiple devices on fiber optic loops 24V in A560 User Manual A560 UM 150413 Page 18 of 67 PSI System Controls and Diagnostics 9 4 Connecting fiber optics Each fiber optic port comprises a transmitter connector tx light grey and a receiver connector rx dark gray The loop 1s a chain of tx
13. is common to all Pyramid G2 devices contains the following indicators Comms bar When moving this indicates that messages from the A560 are being received by the PTCDiagnosticG2 program The message frequency is displayed Connected LED When lit this indicates that communications are valid and the system 1s not in error Busy LED When lit this indicates the A560 is busy and cannot respond to inputs Measuring LED This LED has no function for the A560 Error LED When lit an error has been latched The message area will provide details On the left below the banner there is a graphic display of the data with controls for how the data is plotted below it This area is used if the A560 collects data from devices on its fiber optic loops using the Real Time Processing feature Below the graphic is a message window which reports all the commands issued to the A560 by the PTC Diagnostic program and the corresponding acknowledgements Generally you can ignore this display but it will be valuable for diagnosis if you have any operating problems On the right there is a screen area which changes according to which display option you select A560 User Manual A560 UM_ 150413 Page 29 of 67 PSI System Controls and Diagnostics Real Time Controls for configuring and executing functions such as map Processing processing An example would be for general purpose I O device connected to the A560 such as an MIO to put out a sequence of analog
14. is still intact The code has be loaded in individual pieces rather than as an integrated zip package as 1s done in the normal firmware update process CAUTION We recommend that you contact Pyramid Technical Consultants before attempting the A60 Recovery process as it 1s requires low level operations not designed for normal users of the device It is possible to corrupt the memory such that the device can only be recovered at the factory if the process is not completed correctly 20 1 Determining that the bootloader is intact but the application code memory is corrupt The bootloader is the first piece of code that runs on power up It verifies the integrity of the most critical parts of the flash memory and NIOS processor memory While it is testing the LEDs blink in the walking up pattern shown in section 17 4 However if the bootloader finds a problem it will blink the LEDs in an alternating pattern o o e O 0 O 0 O o e 0 O O Figure 30 LED sequence if the bootloader detects an error Confirm that the bootloader is active and available to load new code by sending a ping to the A560 on 192 168 100 102 20 2 Re loading the firmware 1 Make a direct network connection to the A560 from a computer see figure 8 We recommend that you ensure that only the A360 can be reached for example by temporarily A560 User Manual A560 UM 150413 Page 54 of 67 PSI System Controls and Diagnostics disabling any other net
15. loop_9 ios loop 1 Figure 12 Tree display of discovered and connected devices Clicking on any highlighted entry in the table will open a window for that device If you click on the A560 entry a window for the A560 itself will open and you will see messages in the message area as the A560 adds your PC as a host If there are fiber optic loops with no devices connected then you will see timeout errors in the message from the A560 s failure to connect loop devices in its initial search This is normal and you can clear the error by pressing the clear button Sil at the bottom of the display A560 User Manual A560 UM 150413 Page 28 of 67 PSI System Controls and Diagnostics 5 PTC Diagnostic 5 a560_testing 192 168 100 20 ial x FH m9 86 Discover 19 Stop System Start System Tile Windows O Initiate All WIE Connected Busy Measuring Error BB 192 168 100 20 a560 testing Initiat nitiate E loop 1 flee M40_1 3 OE Real Time Processing loop Em 10 3 Enable RT Map Processing oop 3 IV Collect data while Idle Upload Configuration oop 7 a oop 8 Initiate Map Row 0 E oop 9 Abort Map Data Configuration Map Instant Map Rows NYR State Idle Waiting for Trigger Last Error Fiber message timeout Figure 13 Opening the A560 window 11 3 Screen layout The A560 user interface screen is divided into two halves plus a top banner area The top banner
16. 1 aoutl wire analog out 1 gt channel name e ml10 1 aout2 wire analog out 2 gt channel name c m0 1 doutl wire digital out 1 gt z channels lt board gt lt fboards gt lt floop gt loops lt floopcontroller gt z loopeontrollers Figure 22 xml file example for real time processing first section The next section is the timeslicedatabase definition which lists the values that will appear on the PTC DiagnosticG2 screen the two M10 analog outputs and two analog inputs in this example The database section 1s the values that will be put into local memory and can be saved to a csv file by the PTC DiagnosticG2 The processes section controls how the map will be executed In this example each line of the map will set the two analog outputs to the map value A560 User Manual A560 UM 150413 Page 38 of 67 PSI System Controls and Diagnostics lt timeslicedatabase gt channel name c mi 1 aoutl if schannel name r mi 1 aini gt channel name c mi0 1 aout p channel name r m10 1 ain gt z timeslicedatabase zdatabase channel name e mi0 1 aoutl gt channel name r m10 1 aini gt channel name c m0 1 aout2 pe channel name x m0 1 ain2 gt lt database gt processes 4 1 Use a process rather than directly setting e 410 1 souti from the map so that the manual DAC setting is not blocked out when not running the Profile process name profile Xl
17. 1010 1 2000 It must be used in accordance with its specifications and operating instructions Operators of the unit are expected to be qualified personnel who are aware of electrical safety issues The customer s Responsible Body as defined in the standard must ensure that operators are provided with the appropriate equipment and training The unit is designed to make measurements in Measurement Category I as defined in the standard The unit must not be operated unless correctly assembled in its case Only Service Personnel as defined in EN61010 1 should attempt to work on the disassembled unit and then only under specific instruction from Pyramid Technical Consultants Inc The unit is designed to operate from 424 VDC power with a typical maximum current requirement of 200 mA An auxiliary power output is provided from which up to 1 1 A 24 VDC can be drawn A suitably rated power supply module is available as an option A safety ground must be securely connected to the ground lug on the case Some of the following symbols may be displayed on the unit and have the indicated meanings A560 User Manual A560 UM 150413 Page 6 of 67 PSI System Controls and Diagnostics Direct current Earth ground terminal Protective conductor terminal Frame or chassis terminal Equipotentiality Supply ON Supply OFF CAUTION RISK OF ELECTRIC SHOCK CAUTION RISK OF DANGER REFER TO MANUAL PbPbO OH A560 User Manual A
18. 43 protected against solid objects greater than Imm in size protected against spraying water A560 User Manual A560 UM 150413 Page 12 of 67 PSI System Controls and Diagnostics Operating environment 0 to 35 C 15 to 25 C recommended 70 humidity non condensing vibration lt 0 2g all axes 1 to 100Hz Shipping and storage 10 to 50C environment 80 humidity non condensing vibration 2 g all axes 1 to 100 Hz A560 User Manual A560_UM_ 150413 Page 13 of 67 PSI System Controls and Diagnostics LCD DISPLAY JOYSTICK KEY SWITCH KEY SWITCH STATE LED we l 19 ONT VIEW 24VDC GATE CONNECTORS POWER IN LEMO REDEL PXG ETHERNET STATUS LEDs BNC N M4 GROUND LUG RELAY OUT RESET INTERLOCK FIBER OPTIC TX ENABLE ENABLED BACK VIEW FIBER OPTIC RX ROTATED U Figure 1 A560 front and rear panels A560 User Manual A560 UM 150413 Page 14 of 67 PSI System Controls and Diagnostics 482 6 19 gt o CO aa 248 8 Figure 2 A560 case plan and side views Dimensions mm A560 User Manual A560 UM 150413 Page 15 of 67 PSI System Controls and Diagnostics 9 Installation 9 1 Mounting The A560 1s intended for 19 rack mount installation or it may be simply placed on a level surface The mounting position should allow sufficient access to rear panel connectors and allow necessary ca
19. 50413 Page 63 of 67 PSI System Controls and Diagnostics 24 Support Manual and software driver updates are available for download from the Pyramid Technical Consultants website at www ptcusa com Technical support is available by email from supportOptcusa com Please provide the model number and serial number of your unit plus relevant details of your application A560 User Manual A560 UM 150413 Page 64 of 67 PSI System Controls and Diagnostics 25 Disposal We hope that the A560 gives you long and reliable service The A560 is manufactured to be compliance with the European Union RoHS Directive 2002 95 EC and as such should not present any health hazard Nevertheless when your A560 has reached the end of its working life you must dispose of it in accordance with local regulations in force If you are disposing of the product in the European Union this includes compliance with the Waste Electrical and Electronic Equipment Directive WEEE 2002 96 EC Please contact Pyramid Technical Consultants Inc for instructions when you wish to dispose of the device A560 User Manual A560_UM_ 150413 Page 65 of 67 PSI System Controls and Diagnostics 26 Declaration of Conformity Declaration of Conformity Issued by Pyramid Technical Consultants Inc 1050 Waltham Street Lexington MA 02421 USA The undersigned hereby declares on behalf of Pyramid Technical Consultants Inc that the referenced product conforms to the provisions as liste
20. 560 UM 150413 Page 7 of 67 PSI System Controls and Diagnostics 4 Models A560 Real time controller with ten fiber optic loop ports A560 User Manual A560 UM 150413 Page 8 of 67 PSI System Controls and Diagnostics 5 Scope of Supply A560 model as specified in your order PSU24 40 1R 24 VDC power supply CAB RJ45 3 RJ45 Cable Ethernet CATS 3 CAB ST HCS 10 ST qty 2 Cable fiber optic ST terminated 10 USB memory stick containing A560 User manual PTC DiagnosticG2 software installation files Test data Optional items as specified in your order OEM customers may not receive all the items mentioned A560 User Manual A560_UM_ 150413 Page 9 of 67 PSI System Controls and Diagnostics 6 Optional Items 6 1 Power supplies PSU24 40 1R 24 VDC 40W PSU universal voltage input plug receptacle for standard IEC C14 three pin socket with output lead terminated in 2 pin Redel locking connector PD 8 Eight output 24 VDC power supply unit 19 rack mounting 6 2 Data cables CAB ST HCS 10 ST Fiber optic cable pair 200 um HCS fiber ST terminated with color coded sleeves 10 Other lengths available to order up to 1000 6 3 Power cables CAB LR 3 REDEL Cable 2 1mm threaded jack termination one end two pin Redel other end 3 for power connection to PD 8 supply A560 User Manual A560_UM_ 150413 Page 10 of 67 PSI System Controls and Diagnostics 7 Intended Use and Key Features 7 1 Intend
21. 8 100 20 p Add IP Address i i Load System File 192 168 100 20 gt Add IP Address Load System File y Connect amp Discover Subdevices Cancel Figure 11 Discovering the A560 and selecting it for connection y Connect amp Discover Subdevices In some circumstances the discovered devices may include Pyramid tools such as the A60 recovery utility You can 1gnore these When you click on the discovered A560 the Connect and Discover Subdevices button is enabled Click on this to establish the connection to the A560 The System area of the display will show a tree structure with all discovered devices and connected devices highlighted If a connected device is a loop controller like the A560 then the loops will be listed and the slave devices will be shown in their loop order and with their loop addresses shown Note that it is not necessary to have the devices connected in any particular address order on a loop but that there should be no duplicate addresses on one loop In the example shown the A560 has three devices on its loop ports one on each of loop one loop two and loop four A560 User Manual A560 UM 150413 Page 27 of 67 PSI System Controls and Diagnostics 2 5 x A lt I g Discover Stop System 49 Start System Tile windows ysy Initiate All System ON PTC Diagnostic 5 E loop 1 i dam 111401 E loop_2 loop 3 E loop_4 eum H201 H loop 5 H loop amp z loop 7 x loop 8
22. A560 Real time Controller User Manual Pyramid Technical Consultants Inc 1050 Waltham Street Suite 200 Lexington MA 02421 USA US TEL 781 402 1700 FAX 781 402 1750 EMAIL SUPPORTOPTCUSA COM Europe TEL 44 1273 492001 PSI System Controls and Diagnostics 1 Contents 1 CONTENTS lt iia 2 2 FIGURES za 5 3 SAFETY INFORMATION mm aoai 6 4 MODELS heit tdt N ida 8 5 SCOPER OE SUPPTIY ion 9 6 OPTIONAL ME I o do IR 10 O NS AS er iu BAM ad case cU Red ALL MMC Ged Ml Md UPC DR P MIL ted ei tn CLR ERGs etna 10 02 MDATACABDE Suse ia ilt mie MD Ieri Dc pone Mot terre a dios bee di il Me he cd eos be dient iren tee le 10 50 9 POWER CABLES GI sies nuts assumi cre eM dp cR DA ea DM S e Re Itb Le teet suc LAM AE MCCC e a beanest 10 7 INTENDED USE AND KEY FEATURES ci n cid ae sae a ei eos 11 Tel INTENDED USE trio at oro orienta lorca ic dond 11 4 25 A da MI MeL D Of DE OCC ote one 11 8 v ul o Us D OE EP TION eec p Xp cd xd 12 9 ENSIT AT RAT ICON etit secu te Min su MIS DEDI E ea 16 SUE MOCRO AAA II ea M E uM E SA 16 9 2 GROUNDING AND POWER SUPPLY sccsceccsceccececcscecccsceccececeecscescececscescscsececssescecescecscscescscesescesescescecesccess 16 93 EOOP CONEICC NN OA 18 OA CONNECTING FIBER OPTEN load 19 I0 OVERVIEW OF THE A560 ccno E A E a oa 20 10 1
23. A560 UM 150413 Page 44 of 67 PSI System Controls and Diagnostics C CS Studio amp M10 demo opi 3 ES Deflector 1 56 10 40 60 20 11 Vrrril a 80 3 MEE TA P c os pu 76 85 100 KA 14 77 20 yt Y kv mA am Local control on t s Local Enable 9 Fault 5 Enabled Figure 26 Example power supply user control created using CS Studio BOY CAUTION Don t try to control the devices connected via theA560 simultaneously from an EPICS client and from the PTC DiagnosticG2 The results will be confusing In particular if you attempt to run the IG2 service and PTC DiagnosticG2 on the same computer the communications will conflict A560 User Manual A560 UM 150413 Page 45 of 67 PSI System Controls and Diagnostics 16 Connectors 16 1 Rear panel connectors 16 1 1 Ethernet communications RJ 45 jack To mate with standard RJ 45 plug Auto MDIX facilty cable can be direct or crossover type 16 1 2 Enable Status port One Weidmuller Omnimate SL 179348000 8 pin connector pq a a ITT Enable Enabled Mode i 24V Cmd Status Key 16 1 3 Interlock port One Weidmuller Omnimate SL 179345000 5 pin connector four pins used TA HE l l 24 n c l 16 1 4 Relay port One Weidmuller Omnimate SL 179344000 4 pin connector EX SERE 24 Relay 16 1 5 Gate in signal BNC connector TTL levels 16 1 6 Gate out signal BNC con
24. C Time Remaining 169 seconds E 3 Figure 16 Firmware update status window When the update 1s complete you should reboot the device by power cycling it and check the Properties screen area to ensure that the new versions are correctly reported If the process does get interrupted it is possible that the A560 will not be able to do another update because core programs have become corrupted In this case you should contact Pyramid or your supplier who can organize a recovery 11 4 2 Changing the IP address You can alter the A560 fixed IP address to any valid setting or set the mode to DHCP 1f you are connected via a router that provides a DHCP address allocation service A560 User Manual A560 UM_ 150413 Page 31 of 67 PSI System Controls and Diagnostics ON 1P Configuration ajx Mame a560_testingl Mode stati IP Address 192 166 100 20 Met Mask 255 255 255 0 Gateway 192 168 100 1 System Log 192 168 100 28 Note Changing these settings will cause you to lose communication with the device Cancel Figure 17 IP address configuration dialog Note that the address change takes effect immediately so you will lose communication in the session you were running Simply click 69 7 on the Diagnostic to rediscover the device If you have set the IP address outside the subdomain that 1s accessible to your host computer you will need to change the IP address of the computer so that it is in the same subd
25. D 1 56 enabled wire digital in 1 gt lt channel name r ESD 1 56 fault wire digital in 2 gt lt channel name r ESD 1 56 local wire digital in 3 gt lt channel name c ESD 1 56 enable wire digital out 1 gt lt channel name c ESD 1 56 local wire digital out 3 gt lt channel name c ESD 1 56 reset wire digital out 4 gt lt channel name c ESD 1 56 fault wire digital out 2 gt lt channel name c ESD 1 56 mA wire analog out 2 scaleB 2 limitLow 0 limitHigh 20 gt lt channels gt lt board gt lt boards gt lt loop gt lt loops gt lt loopcontroller gt lt loopcontrollers gt lt interpreter gt lt devices gt lt epicscas type epicscas name epics server gt lt devices gt lt interpreter gt lt system gt Figure 27 Example xml system configuration file for EPICS Once you have created and saved your system file you can run the IG2 service executable If the server has a display you will see a console window that shows the connection process then records subsequent control value changes sent to the devices via the A560 The names you declared will now be recognized as process variables by any EPICS compatible client program As an example the following screenshot shows a user interface for the ES Deflector 1 56 power supply created in the CS Studio BOY OPI editor The IG2 server and the GUI were running on a standard Windows PC A560 User Manual
26. INE sec Ae A Aaa ECEE Nae ENGS 20 PTC DiagnosticG2 instalacion a NEEE a a aaa 24 Direct patch cable connection from host computer to A560 esscsssssscccccsssssececcssssscccossssssseccssssssseesoo 25 Configuring the IP address on the host computer sseeccsesssseeecccssssseecocossssecocccssssccecccsssssceoosssssseeeosssso 25 Ping test of th Ethernet cOnnectlOn ecco eee eoe eeve ee ele s Ceo bea eae e eene Pe ee e ae ais a a eaae 26 Discovering the A560 and selecting it for connection eee ecce ee eee eee eee eee eee e eaaet ee eeeous 27 Tree display of discovered and connected devices eee eee Leere eere e eee eee eee eee ee eee eese 28 Opening the A560 WIBIOW uou eoe viee ede AA a sosdde dU sop daa die a 29 Firmware Update piel 30 aaa ea AAA bee ee eere Posee dins eet eee pte EU DU 31 Firmware update status WIDdOW 52 eie te eee Re eaaa Enea Ne QR EN EE FEN e e ERN EER RE Sero E ONEA a Sans 31 IP address configuration dialog did 32 Direct Ethernet CONNECTION iii raS EEan Eaa Sa Aaa n 33 Network connection via Witkin iia O si 34 Network Incl dino route ssena aaaea A EEEN ERNE NEE EENE NEEE E ETSA 34 Realtime proc ssing controls iia IE IRA a AENEA Aau OEE EE AE aE AESi 37 xml file example for real time processing first section ssssseecccssssscceccssssscecccossssccecosssssececssssssseeoso 38 xml file example for real time processing CONTINUE
27. Manual A560 UM 150413 Page 30 of 67 PSI System Controls and Diagnostics n A Open G2 Firmware File e ee me OD i PTCSoftware Firmware A360 v Search A360 Organize y New folder a HU Name Date modified Type Size E Comput e pls 3 A360 Firmware 0 6 17 6 zip 11 21 2012 7 14 PM Compressed zipp 4 667 KB 5 i B 4 A360 Firmware 0 6 17 9 zip 12 3 2012 3 55 PM pressed zipp 4 635 KB a A0 F 4 A360_Firmware_0 6 17 23 zip 1 30 2013 5 35 PM pressed zipp 4 643 KB tc t a D a idi iin E 4 A360_Firmware_0 6 24 7 zip 8 13 2013 4 21 PM Compressed zipp 4 677 KB tc t HK CO HARIAN h A360 Firmware 0 6 25 15 zip 10 9 2013 3 51 PM Compressed zipp 4 640 KB IE Design Docs on ptc sharepoint ptcusa com e No pre labl 4 A360_Firmware_0 6 25 17 zip 10 24 2013 4 13 PM Compressed zipp 4 640 KB IE I3200 on ptc sharepoint ES Management Review Meetings on ptc sharepoint Nf My Web Sites on MSN E Quality Manual Contents on ptc sharepoint IE Scan Dose on ptc sharepoint IE Test Procedures on ptc sharepoint E File name A360_Firmware_0 6 25 17 zip y PTC G2 Firmware Archives zi v Figure 15 Selecting the firmware file While the update is taking place you will see a countdown of the time remaining and you can see detailed activities reported in the message window Updating Firmware DO NOT TURN OFF DEVICE POWER DO NOT CLOSE THE DIAGNOSTI
28. Xx File Edit View Processing Tools Window Help E ds Hardware Setup EthernetBlasterII on 192 168 100 120 EthernetBlasterII Mode JT AG M Progress Enable real time ISP to allow background programming for MAX II and MAX V devices File Device Checksum Usercode Program Verify Blank Examine Security Erase ISP pi Start Configure Check Bit CLAMP OPER Factory default PFL image EP3C55F484 002CA206 FFFFFFFF VEINS 4 A60 1 0 12 pof CFI 128Mb E35A19BD Page 0 El ad Auto Detect j Delete a Add File ll Change File Ej Save File Core diu CFI 128Mb Down Lo Sssuuuuuug mol Figure 35 Quartus programming software screen 12 Click Start programming may take a minute or two The progress bar will count through at least twice 13 If the programming is successful use the A60 Recovery utility to complete the process section 19 A560 User Manual A560 UM 150413 Page 60 of 67 PSI System Controls and Diagnostics 22 Maintenance The A560 does not require routine maintenance except to clear any dust accumulation in the fan filter There are no user serviceable parts inside 22 1 Cooling fan maintenance If there 1s buildup of dust in the filter you should clear this by vacuum cleaning in situ or by removing the filter element and cleaning it separately with an air jet Note that detaching the filter element a
29. ant to load to expose the individual FPGA_flash bin and zImage flash bin files 5 Select the FPGA tab If there are errors in the FPGA code image there will be red LEDs on the screen and you should re load the code Browse for the FPGA flash bin file that you unzipped then click the Erase and Update Firmware button 7 7 imwa y Allow the firmware to load 6 Select the Software tab If there are errors in the operating system code image there will be red LEDs on the screen and you should re load the code Browse for the zImage flash bin file that you unzipped then click the Erase and Update Firmware button Peer tm Allow the firmware to load 7 Reboot the device You should now be able to connect normally with the PTC DiagnosticG2 software on the default IP address 192 168 100 20 A560 User Manual A560 UM 150413 Page 55 of 67 PSI System Controls and Diagnostics 8 Do a complete firmware in the normal way see section 11 4 1 This stage is necessary to load secondary processor code and secondary FPGA code 9 Reboot the device and confirm you have normal operation A560 User Manual A560 UM 150413 Page 56 of 67 PSI System Controls and Diagnostics 21 Loading the A60 Bootloader If the bootloader 1s corrupted in your A560 the device will not boot up and only the top power LED will be on If this 1s the case you need to reprogram the bootloader CAUTION We recommend strongly that you contact Pyramid Technical Consu
30. ble bend radii 60 mm minimum clearance is recommended at the ends of the device The rear panel fan exit should not be obstructed Free convection should be allowed around the back and sides of the case 9 2 Grounding and power supply A secure connection should be made using a ring lug from the M3 ground lug to local chassis potential 24 VDC power should be provided from a suitably rated power supply with the following minimum performance Output voltage 24 0 5 VDC 1000 mA minimum 3000 mA maximum Ripple and noise lt 100 mV pk pk 1 Hz to 1 MHz Line regulation lt 240 mV The A560 includes an internal automatically re setting PTC fuse rated at 1100 mA for its own circuitry A 200 mA fused 24 V output is available on the rear panel interlock connectors for use in 24 V logic arrangements A560 User Manual A560_UM_ 150413 Page 16 of 67 PSI System Controls and Diagnostics Fan FS 200 mA OO __ gt 24V logic Redel PXG FS 200 mA OO gt 4 24V 22 uF 35V lt J24Vrtn Transorb Transorb oV oV Transorb 9 24V uni Chassis il 15R DGnd Figure 3 24 volt input circuit The external supply should in no circumstances be rated higher than the connector limit of 5 A A560 User Manual A560_UM_ 150413 Page 17 of 67 PSI System Controls and Diagnostics 9 3 Loop configurations The simplest use of the A560 1s to provide a means of connecting Pyramid devices to an Ethernet port The schematic example
31. bytes 32 time lt 1ms 20 bytes 32 time lt 1ms A11 rights reserved TTL 64 TTL 64 TTL 64 TTL 64 Ping statistics for 192 168 100 20 Packets Sent 4 Received 4 Lost O 0 loss Approximate round trip times in milli seconds Minimum Oms Maximum Oms Average Oms C Users John gt m Figure 10 Ping test of the Ethernet connection The Windows firewall may block communication with the A560 Itis simplest to start by turning off the firewall while you are testing To maintain security you can disable any wireless adaptor on the PC while you are doing this Once you have established communication then you can try restoring the firewall and set up permissions for the PTC Diagnostic to communicate through the firewall Contact Pyramid Technical Consultants Inc for latest information about firewall permissions 6 Start the PTCDiagnosticG2 software It will start with the Discover Devices dialog open Click on Discover Controllers and the software will search all IP addresses within its available network looking for compatible Pyramid devices If you have the simplest possible network it should find only the A560 you are working with A560 User Manual A560 UM_ 150413 Page 26 of 67 PSI System Controls and Diagnostics ON PTC Diagnostic Discover Devices 2 xi ON PTC Diagnostic Discover Devices 2 x 192 168 100 20 a560 testing Ding Looking for Loop Controllers 16 6 Discover Controllers 192 16
32. ced to support the G2 range of Pyramid Technical Consultants Inc products which feature embedded Linux processors and built in Ethernet interfaces It 1s not compatible with the PSI Diagnostic program which supports previous Pyramid products However the PTC Diagnostic G2 program will be extended in the future to add support for all the previous products The PTC DiagnosticG2 includes a device discovery feature which allows it to build a system configuration map based on responses from all connected devices This is very useful for service and fault finding However if you are using A560s in a large system with dedicated host software written for your application it is likely that there will be a fixed system configuration In other words the Diagnostic will adapt to changes in your setup such as the addition of another device on a fiber optic loop but a program that sets a fixed configuration will not see the device until its configuration file is updated Your A560 was shipped with a USB memory stick with the installation files you need We recommend that you copy the files into a directory on your host PC Check the Pyramid Technical Consultants Inc web site at www ptcusa com for the latest versions 11 1 Installation The program runs under the Microsoft Windows operating system Copy the installer file PTCDiagnosticSetup Vx_xx ms1 to the hard drive of the host computer where x xx is the version of the Diagnostic The program will run on
33. cessing set automatically if you load a valid xml file Collect data while If this box is checked then the parameters you have defined in the idle timeslicedatabase will continue to be updated and displayed even after map execution has finished Auto repeat If you check this box after loading valid xml and map files the map will be repeated continuously You can set the row in the map file that you wish to start from Abort map Not used Data instant Digital display of the parameters you have defined in the timeslicedatabase The check boxes allow you to display or Data rows As the map 1s executed a table of timestamps and the parameters you have defined in the database builds up The file save button kl allows you to save the values as a csv file Configuration This tab displays the configuration you set up in the xml file in tree format This tab displays the map that has been loaded A560 User Manual A560 UM 150413 Page 41 of 67 PSI System Controls and Diagnostics 15 Connecting Devices using EPICS 15 1 What is EPICS The Experimental Physics and Industrial Control System EPICS http www aps anl gov epics 1S A set of Open Source software tools libraries and applications developed collaboratively and used worldwide to create distributed soft real time control systems for scientific instruments such as particle accelerators telescopes and other large scientific experiments EPICS uses Client Server and Publish
34. d Refer to the document Extension of testing and analysis to the PTC product line December 10 2007 and its continuations and the 1400 Technical Construction File for detailed testing information Product A560 System Controller Year of initial manufacture 2012 Applicable Directives 73 23 EEC Low Voltage Directive Laws for electrical equipment within certain voltage limits 89 336 EEC EMC Directive Laws relating to electromagnetic compatibility Applicable Standards IEC 610101 2002 2 Edition UL 61010 1 2004 EN 61326 1997 A1 1998 A2 2001 EN 55011 1998 A2 2002 EN 61000 6 2 2001 Electromagnetic Compatibility Generic Standard Immunity for Industrial Applications Issuing Agencies Safety TUV Rheinland North America 12 Commerce Rd Newtown CT 06470 USA EMC TUV Rheinland North America 12 Commerce Rd Newtown CT 06470 USA Applicable Markings TUV FCC CB J Authorized by gt 9 5 a Pyramid Technical Consultants Inc Date Py The Technical Construction File required by theses Directives are maintained at the offices of Pyramid Technical Consultants Inc 1050 Waltham Street Lexington MA 02421 USA A copy of this file is available within the EU at the offices of Pyramid Technical Consultants Europe Ltd Suite 3 Unit 6 7 Henfield Business Park Henfield BN5 9SL United Kingdom A560 User Manual A560 UM 150413 Page 66 of 67 PSI System Controls and Diagnostics 27 Revision History
35. ddress message is only shown if the A560 is configured for DHCP address assignment The IP xxx xxx xxx xxx message is only shown if the A560 is configured to a Static IP address where xxx xxx xxx xxx 1s that address When a host system connects to or discovers the A560 an announce message is displayed very briefly Announced Host XXx XXx XXx yyy where xxx xxx xxx yyy 18 the IP address of the host computer When the A360 connects to a network the display changes to IP XXX XXX XXX XXX where xxx xxx xxx xxx 1s the IP address of the device If you are connecting via DHCP the address may show as the default 192 168 100 20 before the assigned address 1s displayed If you change the IP address or a new address 1s assigned by the router then the display will alter to reflect this after a few seconds 13 2 Enhanced display A future firmware release will provide a comprehensive diagnostic display The front panel Joystick will be used to step through the lines of the display A560 User Manual A560 UM 150413 Page 36 of 67 PSI System Controls and Diagnostics 14 Real Time Processing The A560 can provide a powerful real time processing service for devices connected on its fiber optic loops This can be achieved by custom code written to your specification by Pyramid Technical Consultants Inc or by using the A560 Real Time Processing function Real Time Processing Enable RT Map Processing T Collect data while Idle U
36. echnical Consutants inc PTCDiagnosticG2 is being installed Please wait ENEN h 9 33 Cancel Figure 7 PTC DiagnosticG2 installation The installer will create a subdirectory in the Program Files directory containing all the executables and configuration files and create shortcuts on your desktop and in the Start menu 11 2 Connecting to the A560 The following steps take you through the process of connecting to the device 1 It is simplest to start with a direct connection from your host computer to the A560 using a CATS5 or CATO Ethernet cable as shown in figure 8 The network cable can be a patch or a crossover type the A560 automatically adjusts itself to suit Later when you have confirmed reliable communication then you can move the A560 onto a general local area network if required A560 User Manual A560 UM 150413 Page 24 of 67 PSI System Controls and Diagnostics Figure 8 Direct patch cable connection from host computer to A560 2 The A560 is set with default static IP address 192 168 100 20 at shipment Once you have a connection you can change this setting as required Set up your host PC Ethernet port with a fixed non conflicting IP address in the same subnet range for example 192 168 100 11 a Internet Protocol Version 4 TCP IPv4 Properties E et General You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask y
37. ed Use The A560 1s intended to provide convenient high performance connection of Pyramid devices via fiber optic loops and real time processing of the data Connection to a host computer system is via a standard Ethernet interface A set of interlock relays allow the A560 to gate external processes based on the incoming data and the state of health of the A560 itself The A560 is thus able to form part of a safety critical control system such as control of an accelerator used for medical purposes Fiber optic communications provide perfect electromagnet noise immunity and the ability to link devices at different electrical potentials Up to fourteen devices can be connected on each of the ten loop ports although smaller numbers are recommended if communication speed 1s critical The A560 has design features which make it tolerant of electrically noisy environments but the place of use is otherwise assumed to be clean and sheltered for example a laboratory or light industrial environment The unit may be used alone or networked with other devices and integrated into a larger system Users are assumed to be experienced in the general use of local area networks and to be aware of the dangers that can arise in high voltage circuits 7 2 Key Features Compact 1U design LCD status display with joystick navigation Standard Ethernet port supporting TCP IP and UDP Ten fiber optic loops each supporting up to fourteen devices Process control rela
38. figuration DC DC converters create the voltage rails for the internal circuits from the incoming 24 V supply A fused 24 V is available on the interlock connectors for 24 V logic configurations 10 1 Communication to the host computer The A560 includes a standard 1000 100 10BaseT Ethernet interface which supports TCP IP and UDP protocols The A560 can serve multiple clients on the network You can either use the G2 Diagnostic host software provided your own custom software using the PTC Controls32 DLL or the Pyramid IG2 program which provides data connection to an EPICS layer using a Channel Access Server With the data available via EPICS you can use one of many EPICS clinet connections that are available including ones for LabView Python Java C Matlab and Control System Studio 10 2 Communication to slave devices The fiber optic interfaces allow devices from the Pyramid range to be connected via robust noise immune 10 Mbit s connections Up to 14 devices can be connected on each loop Message packets are sent out by the A560 and received again when they have passed around the loop loaded with data from the devices The devices can be mixed in any combination Device families include e devices for very low current measurement e F devices for high speed low current measurement e C devices for detector pulse counting e H devices for magnetic field measurement e M B devices for general purpose interfacing e Ndevices fo
39. he EPICS community including interfaces for C CF Java Python Labview and Matlab 1M The Control System Studio or CS Studio http controlsystemstudio github 10 is a set of ready made tools built on Java and Eclipse http www eclipse org that allows users to get started with little or no programming required There are various logging plotting post processing and alarm point tools A fully featured drag and drop user interface editor BOY allows quite complex customized user interfaces to be created with minimum development time 15 2 Installing and Configuring IG2 The IG2 package is available to users of Pyramid products It is supplied as a zip file which should be de compressed and the entire folder moved to the computer that will act as the server The server and the user interface computer can be the same machine The A560 the server and the user interface computer should be able to communicate with each other over your network In the folders you have saved there is an xml file in the service subdirectory that need to be edited to customize your particular setup The format of the file is similar to the real time processing configuration files described in section 12 but there are some differences reflecting the different function IG2 looks for the file system xml in the service subdirectory to establish the configuration of the system You can locate system xml elsewhere than the default location or gi
40. kes the use of DHCP assigned addresses practical Switch Router Figure 20 Network including router You can define the address of this router or some other access point on the network as the default gateway if you want the A560 to be accessible from another network This is optional A560 User Manual A560 UM 150413 Page 34 of 67 PSI System Controls and Diagnostics 12 2 Firewalls Windows Firewall will block one or more of the communication channels required by the A560 We recommend disabling it This is not a particular risk if the network is isolated from the internet or protected behind a router firewall If you must enable Windows Firewall however then you should set up permissions for the programs and data channels that are used If you are using the PTC DiagnosticG2 then inbound and outbound permission should be set for any protocols for the program and inbound permission for RPC TCP messages for local port 111 A560 User Manual A560 UM 150413 Page 35 of 67 PSI System Controls and Diagnostics 13 Front panel LCD 13 1 Firmware 0 6 168 45 and earlier During the power up process the A360 LCD back light turns on and then displays in sequence Initializing Booting Loading MAC address Loading IP configuration A560_1 started Acquiring IP address A560_1 started IP xxx xxx XXX XXX In a future firmware release the string A560_1 will be the name you have given to the A560 The Acquiring IP a
41. ldback Firmware corrupted or absent the A560 and looped devices Check power LED Disconnect power supply and any device using 24V output from A560 wait 5 minutes re try Check power LED Disconnect any device using 24V output from A560 wait 5 minutes re Check rear panel LED power up sequence A560 UM 150413 necessary onsult Pyramid Technical Consultants or your supplier Locate source of excess current demand and fix Locate source of excess current demand Contact Pyramid Technical Consultants You will be advised whether to return the unit or attempt a reprogramming procedure Page 51 of 67 PSI System Controls and Diagnostics 19 Error Codes Pyramid G2 devices like the A560 report status and error codes which can give you more information about problems with your system or the device itself You would see these codes for example in the message area of the PTC DiagnosticG2 software If you are discussing a problem with Pyramid it will be helpful to record any error codes you see If you are developing host software for the A560 you would need to react appropriately 1f a message to the device returns an error code The full set of codes is listed in this section a subset would apply to your particular application The codes with a negative value are shared with the SCPI Standard Commands for Programmable Instruments protocol 21 XMLEmo S ooo 18 RPCBmr 0
42. le Format Images Select Falder Save TEKOO TS TIF M 50 0rns Figure 24 Example analog voltage waveforms produced by map execution The parameters you declared in the timeslicedatabase section of the xml file are plotted in the eraphic area and you can move a cursor and use the horizontal slider to inspect points in the waveforms The strip chart display 1s the most useful for real time processing displays Note that there 1s a lag of two timeslices between the output values and readback values This lag may be visible if you plot both together a560_1 192 168 1 86 15 Real Time Processing v Enable RT Map Processing V Collect data while Idle Upload Configuration Upload Map Arm Map Auto Repeat Initiate Map Row 0 Abort Map Data Configuration Map Instant Map Rows NVR E 0 2 10 10 15 20 25 30 Time seconds 4 COC Ey GI Auto MET No Avg Zero a COC Ey GI strip A Scope X Histogram 7 325 Samples 4 All B oO Real Time RealTime Processing State Map Executing Waiting For Trigger Last Error x A Figure 25 Display during map execution A560 User Manual A560 UM 150413 Page 40 of 67 PSI System Controls and Diagnostics Other controls and displays on the Real time Processing display have the following purposes Enable RT This check box is set to enable the realOtime processing function It is Pro
43. lso detaches the fan from the case Figure 36 Fan filter removal If the fan fails it is necessary to open remove the lid of the case to access the power connector Due to risk of contamination or electrostatic discharge damage we recommend that you consult Pyramid Technical Consultants Inc before attempting this To remove the lid of the case remove four M2 5 cross head screws from the rear top surface and slide the cover backwards to disengage from the front panel Remember to re attach the fan power connector before re fitting the cover A560 User Manual A560 UM 150413 Page 61 of 67 PSI System Controls and Diagnostics Figure 37 Fan power connector 2 pin Molex The A560 is fitted with a 1 1 amp automatically resetting positive temperature coefficient PTC fuse in the 24 VDC input No user intervention is required if a fuse operates due to overcurrent The fuse will reset when the overcurrent condition ends A560 User Manual A560 UM 150413 Page 62 of 67 PSI System Controls and Diagnostics 23 Returns procedure Damaged or faulty units cannot be returned unless a Returns Material Authorization RMA number has been issued by Pyramid Technical Consultants Inc If you need to return a unit contact Pyramid Technical Consultants at support ptcusa com stating model serial number nature of fault An RMA will be issued including details of which service center to return the unit to A560 User Manual A560 UM 1
44. ltants before attempting to load the bootloader as it requires technical operations including direct connections to the hardware The procedure not designed for normal users of the device It is possible to damage the circuit or corrupt the memory such that the device can only be recovered at the factory 1f the process is not completed correctly Warranty will be void unless the process is done under direction of Pyramid CAUTION ESD SENSITIVE DEVICE You must observe full ESD working practices when working inside the A560 and making connections to the circuit boards Do not proceed if you are unaware of ESD working practices 21 1 Equipment and software needed Altera USB Blaster FPGA programmer USB Blaster to JTAG adaptor Altera Quartus II programming software free download at http dl altera com product qprogrammer tabs 4 A560 User Manual A560 UM 150413 Page 57 of 67 PSI System Controls and Diagnostics Figure 32 USB Blaster and JTAG adaptor 21 2 Re writing the bootloader 1 Obtain the zip file Bootloader Program Docs zip 2 Unzip and move all files 1n Bootloader Program Docs zip to a directory on the programming computer Make sure A60 cdf and A60 1 0 12 pof are in the same directory 3 Connect the A60 JTAG adapter to the USB Blaster cable being careful that the cable end is correctly centered on the adaptor plug This is a straight through adapter so it does not matter which way round you have it 4
45. nector TTL levels A560 User Manual A560 UM 150413 Page 46 of 67 PSI System Controls and Diagnostics 16 1 7 Fiber optic loop ports Ten pairs of HFBR ST bayonet connectors suitable for 1 mm plastic or 200 um silica fiber 664 nm visible red light Dark casing receiver Light casing transmitter O Rx Tx 16 1 8 24 VDC power input Two pin Redel PXG M0 2GG NG female To mate with Redel PAG MO 2 type or PFG M0 2 type free plugs Suitably terminated 24 V power supplies and leads are available from Pyramid Technical Consultants Inc Pin 1 24 VDC Pin 2 24 V return PSU OV 16 1 9 Ground lug M4 threaded stud To mate with M4 ring lug A560 User Manual A560 UM_ 150413 Page 47 of 67 PSI System Controls and Diagnostics 17 Controls and Indicators 17 1 Front panel controls 17 1 1 Joystick Miniature joystick with push button action Reserved for future use for display scrolling 17 1 2 Keyswitch Two position switch to select Normal operation mode or Diagnostic mode Key is retained when in Diagnostic Mode 17 2 Rear panel controls 17 2 1 Reset button Momentary push button that forces a warm reset of the on board processor Also used during boot to force the default IP address 192 168 100 20 17 3 Front panel indicators 17 3 1 LCD Forty column by two row backlit alphanumeric display used to show network status In future firmware releases it will also display diagnostic 1nformation 17 3 2 P
46. omain as the A560 11 4 3 Restoring the default IP address You can force the A560 to restore its default IP address of 192 168 100 20 by power cycling and keeping the reset button pressed from the first 2 3 seconds while it boots up A560 User Manual A560 UM 150413 Page 32 of 67 PSI System Controls and Diagnostics 12 Using the A560 on a network 12 1 Network configurations The A560 uses TCP IP and UDP communication over standard local area network hardware Addressing 1s using the IP4 standard and it supports static and dynamic DHCP address assignment The device can be configured via the PTC DiagnosticG2 via the serial interface or by your own host software using the appropriate procedure calls Most control and data acquisition systems are set up with fixed addresses assigned by the network administrator It is also typical to isolate such networks from the internet to prevent unauthorized access and to allow operation without firewalls which can disrupt communications In order for the host computer and the A560 to communicate they must be within the same subnet It is typical to limit a local network to 256 addresses by setting the IP4 subnet mask to 255 255 255 0 Then the A560 and the host must have the first three bytes of their addresses common and must differ in the last byte For example the host could be 192 168 100 11 and the A560 192 168 100 20 The last byte must also not conflict with any other devices on the same
47. our network administrator for the appropriate IP settings Obtain an IP address automatically 9 Use the following IP address IP address 192 168 100 11 Subnet mask 255 255 255 Default gateway Obtain DNS server address automatically o Use the following DNS server addresses Preferred DNS server Alternate DNS server Validate settings upon exit Figure 9 Configuring the IP address on the host computer 3 Turn on 24 V DC power to the A560 but make no other connections The power LED on the rear panel should illuminate when the power is applied and the cooling fan will start up While the device is booting the three lower LEDs on the rear panel cycle When the device is ready the Ethernet and power LEDs only should be illuminated 4 Make the Ethernet connection from the host PC to the A560 You should see activity on the LEDs that are mounted in the A560 RJ 45 connector Check that you can ping the device from a command window prompt A560 User Manual A560 UM 150413 Page 25 of 67 PSI System Controls and Diagnostics C Windows system32 cmd exe ee Sl Microsoft Windows Version 6 1 7600 Copyright c 2009 Microsoft Corporation C Users John gt ping 192 Pinging 192 168 100 20 Reply from 192 168 100 Reply from 192 168 100 Reply from 192 168 100 Reply from 192 168 100 168 100 20 with 32 bytes of data 20 bytes 32 time lt ims 20 bytes 32 time lt 1ms 20
48. output voltages while measuring one or two analog inputs Interlocks Test utilities and readbacks for the interlock functions Properties Firmware version display and update controls and IP address setting 11 4 Properties 11 4 1 Firmware update The A560 has three embedded firmware installations which need to be compatible with each other The installations are the Linux operating system the NIOS processor real time application and the FPGA programs for primary and secondary FPGAs In order to simplify the task of updating the firmware and ensuring the versions are all compatible Pyramid Technical Consultants Inc releases A560 firmware as a single integrated file which 1s unpacked and uploaded to the correct memory areas by the software You should ensure that the A560 and the host computer will not be disturbed for the four minutes approximately that the update requires To perform the update click the Update All Firmware button on the Properties screen area The software will now warn about the update process and ask if you want to proceed PTC Diagnosti EX bi Warning This device firmware update will take approximately 3 minutes You cannot power down the device during this period Would you like to proceed C9 Cas Figure 14 Firmware update warning Navigate to the update file which is typically about 4 5 Mb in size and has filename A560 Firmware x x x x zip where x x x x 1s the version number A560 User
49. ower indicator Pyramid triangle logo illuminated when device is powered 17 3 3 Keyswitch state indicator Orange LED illuminated 17 4 Rear panel indicators Four green LEDs 17 4 14 Power Green LED 5 VDC and thus 24 VDC power is present A560 User Manual A560 UM 150413 Page 48 of 67 PSI System Controls and Diagnostics 17 4 2 Active Green LED Not currently used 17 4 3 Ethernet Green LED Ethernet commands are being received The on state 1s stretched so that it can be seen This LED does not illuminate for pings 17 4 4 FiberOptic Green LED The A560 is servicing its fiber optic ports 17 4 5 Power up sequence On power up while the A560 is booting the power LED is lit and the lower three LEDs illuminate in a repeating sequence o o o e O 0 O O o o o e O 0 O Figure 29 Normal power up LED sequence When a successful boot is completed the Power and Ethernet LEDs will stay illuminated When a connection to the host computer 1s established and the A560 activates its fiber optic ports the FiberOptic LED will also illuminate 17 4 6 RJ 45 indicators Green LEDs incorporated in the Ethernet connector show that a connection has been established left hand LED and that messages are passing right hand LED A560 User Manual A560 UM 150413 Page 49 of 67 PSI System Controls and Diagnostics 18 Fault finding Unable to Incorrect IP address Check settings of Use consistent IP communicate via for A560 o
50. pload Map Arm Map li Auto Repeat Initiate Map IRow 0 Abort Map Figure 21 Real time processing controls The system is described in detail in the following Pyramid Technical Consultants documents which are available on request PTC1 9 247 A60 Real Time Controller Software and Configuration Architecture PTC1 9 679 A60 Real Time Controller Calculations The feature allows various parameters to be set on devices connected on the fiber optic loops values to be read back and logged to databases computations to be performed and algorithms to be executed We shall use a basic example to illustrate real time processing A sequence of output voltages are delivered from an M10 general purpose interface unit while readback data is logged simultaneously 14 1 Setting up real time processing To set up real time processing you need to tell the A560 which parameters are to be set and which to be read back The configuration is set up in an xml file Full details of the xml schema are given in reference documents The sequence of output values is defined in a map which is simply an ASCII csv table of numeric values The xml file is shown in two parts below It starts with standard header text to set up the xml schema The map section lists the control values that will be read from the map file in successive columns In this case the map will comprise two analog output voltages The 1oopcontrollers section tells the PTC
51. r actuator control Visit the Pyramid websites www ptcusa com and www ptceurope com to see the full range A560 User Manual A560 UM_ 150413 Page 21 of 67 PSI System Controls and Diagnostics Note that devices share the loop bandwidth so you should be aware of the tradeoff between system complexity and speed particularly when connecting multichannel devices that generate data at high rates 10 3 Embedded software The A560 runs an embedded version of the Linux operating system on the Ethernet NIOS processor implemented in the FPGA Three firmware files including the operating system make up a full release You can update with a single zip file which integrates all the releases and thus ensures that you have compatible versions There is a bootloader program which is installed at the time of manufacture This is not altered when the firmware is updated A560 User Manual A560 UM 150413 Page 22 of 67 PSI System Controls and Diagnostics 11 Getting Started using the PTC Diagnostic G2 Host Program The PTC DiagnosticG2 1s a stand alone program which allows you to read graph and log data from devices connected to the A560 and set all the acquisition control parameters It also provides access to A560 utilities and the A560 Real time Processing feature The Diagnostic uses the same function library that 1s exposed for users who develop their own host applications and therefore also serves as a debugging aid PTC DiagnosticG2 was introdu
52. r host not A560 host PC addresses Ethernet in the same subdomain DHCP server has Rediscover using Update any assigned a new IP PTC DiagnosticG2 configuration files that address assume a particular address Messages being Disable firewall and Either run with blocked by Windows recheck Firewall disabled or Firewall set up permissions for the A560 traffic Messages being Disable anti virus Set up allowed blocked by anti virus software channels for A560 software messages Unexpected changes to Another host is Change IP address Set up IP addresses A560 connected communicating with and subnet masks to Use a direct cabl devices the A560 ipeo prevent conflicts connection instead of a network Unable to connect Fiber connections Check loops ensure Correct connections devices on fiber optic crossed tx rx sequence 1s use color code fiber loop correct optics to aid connections Duplicate addresses Check address Ensure no duplicate on a loop settings settings Real time processing Rediscover using Add device to xml file xml file does not PTC DiagnosticG2 as required expose the device Bad fiber optic cable Replace cable Re terminate or replace cable as necessary A560 User Manual A560 UM 150413 Page 50 of 67 PSI System Controls and Diagnostics A560 loses power No text appears on LCD A560 User Manual incompatibility Internal fuse open External 24V PSU fo
53. scale the values and how you can set up monitoring against tolerance bands The choice of a corresponding working name for each wire is up to the user you may wish to choose something descriptive that 1s relevant to what you are measuring or controlling as shown in the example We nevertheless recommend a naming convention that makes it clear whether a value is a readback or control the prefixes c and r_ are used in the example which particular A560 User Manual A560 UM_ 150413 Page 43 of 67 PSI System Controls and Diagnostics device the value 1s associated with and a number or letter to indicate the channel for multichannel devices xml version 1 0 encoding iso 8859 1 2 gt lt system xmlns http www ptcusa com xmlns xsi http www w3 o0rg 2001 XMLSchema instance xsi schemaLocation http www ptcusa com A510 xsd type pyramid gt lt hosts gt lt host ip 192 168 1 64 name PTCE Server localhost true gt lt hosts gt lt loopcontrollers gt lt loopcontroller type A560 name A560 1 ip 192 168 1 86 gt lt loops gt sloop number 5 name Slave device loop gt lt boards gt board type M10 name m10 1 address 1 gt lt channel s gt lt channel name r ESD 1 56 kV wire analog in 1 scaleB 10 gt lt channel name r ESD 1 56 mA wire analog in 2 scaleB 2 gt lt channel name c ESD 1 56 kV wire analog out 1 scaleB 10 limitLow 0 limitHigh 100 gt lt channel name r ES
54. subnet We also recommend that you also avoid using 192 168 100 102 as this address is used by the A60 Recovery utility Addresses with last byte 0 and 255 are reserved for special functions in Ethernet communications Note that if you are communicating with the A560 using Ethernet and you change its IP address then your communication channel immediately becomes invalid You need to rediscover the device if using the PTC DiagnosticG2 or otherwise change your host software setup as necessary If you have moved the A560 into a different subnet for example by setting it to a static address of 192 168 1 20 in the prior example then will also need to the host PC s IP address into the same subnet before you can reconnect The simple static IP arrangement allows you to connect using a direct cable connection as shown in figure 18 or via a network switch as shown in figure 19 Figure 16 Direct Ethernet connection A560 User Manual A560 UM 150413 Page 33 of 67 PSI System Controls and Diagnostics Switch Figure 19 Network connection via switch Static addressing will work if the network includes a router but this arrangement also allows dynamic address assignment by the router If your host software expects devices to be at specific addresses this 1s not appropriate but 1t can be helpful for initial testing and for fluid setups The router will ensure that there are no address conflicts The Discover utility in the PTC DiagnosticG2 ma
55. te orrekte to pete e obe pa re ais 54 21 LOADING THE A60 BOOTLOADER 4iiiteredeoee eee eco eaa p dua eee didas 57 21 1 EQUIPMENT AND SOFTWARE NEEDED id 57 271 2 RE WRITING THE BOOTLOADER ii it dt 58 22 MANTENA NC Do di a id el 61 22 1 COOLING FAN MAINTENANCE Sucia ad mascots 61 25 RETURNS PROCEDURE cia dad 63 2 A A 64 A560 User Manual A560 UM 150413 Page 3 of 67 PSI System Controls and Diagnostics P DISPOS AD ui E 26 DECLARATION OF CONFORMITY viii A a ii 21 REVISION HISTO Yori aaa A560 User Manual A560 UM 150413 Page 4 of 67 PSI System Controls and Diagnostics 2 Figures Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure Figure 9 Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 A560 User Manual A560 front and rear panels id is 14 A560 case plan and side views Dimensions mmm e eee e eee ee eee ee tette eese ees s ss ettet eee ses ss eee eeeeeesous 15 ASIA N 17 Connecting multiple devices on fiber optic loops cce cce eee ee eee eee ee eee e eee eee eese eese s eee eee 18 Mating fiber optie connections emm 19 ASGO CIF CHIU ATCIICE CH
56. to rx connections The A560 sends out a message which passes through each device on the loop dropping off and picking up data The loop must be complete and connected in the right sequence tx to rx for the communications channel to Work correctly The connector is ST bayonet type It is important that you make the connections correctly to ensure good light coupling and to avoid damaging the connector Most ST plugs have a key or lug on the central body This must align with the keyway on the bottom of the socket on the A560 see second picture in figure 5 before the plug can be pushed home with minimum effort The outer shell of the plug can then be rotated while pushing against the spring pressure to engage the bayonet Figure 5 Mating fiber optic connections A560 User Manual A560 UM 150413 Page 19 of 67 PSI System Controls and Diagnostics 10 Overview of the A560 The A560 uses the Pyramid A60 processor card which is common to all Pyramid G2 devices The A60 is based around a powerful field programmable gate array FPGA chip and includes two embedded processor cores One core handles the loop communications the other manages the Ethernet communications The A60 has buffer memory that can be used to enhance the performance of devices connected on the fiber loops Loop ports 1 5 Loop ports 6 10 NR NUI NUI NL AA l l a Gate in pg Cate out _ E 24 V
57. ve it a different name in which case you need to specify the path and file name by means of an argument in the command line that launches IG2 The system file comprises a header section on the xml schema which does not need to change Then comes a description of the user interface host computer descriptions of the fiber optic loop controller devices in your system and descriptions of the devices attached to loops You don t have to describe every device and every input output point that 1s present in your system but only the ones that you expose in the system file will be visible to EPICS The simplified example in figure below shows the format The example is for a fictitious power high voltage power supply called ES Deflector 1 56 An M10 device connected to the supply is configured with address one on loop 1 of the A560 which has IP address 192 168 1 86 One analog voltage output and two analog voltage inputs are exposed together with digital controls and readbacks for typical functions such as enable reset fault and so on The analog voltages are scaled into physical units and their ranges are constrained The convention of wires for Pyramid device process variables common to the real time processing xml files and the fixed names of those wires for each supported product are described in the document ig2_scripting_v pdf where is the document revision number The document also describes in more detail how you can
58. work adaptors on the computer to eliminate the risk you will connect to the wrong device 2 Set the IP address of the computer to 192 168 100 xxx where xxx is a valid last byte but not 102 3 Run the PTC Diagnostic G2 and discover loop controllers You should see only the A60 Recovery device Select it and click Connect Controllers and Subdevices You should see the A60 recovery screen and messages in the message area confirming the connection EX 86 Discover 0 Stop System Start System Tile Windows 5 Initiate All Comms Connected LJ Busy Measuring Error Initiate Get Configuration and Status Error Flags FPGA Software Configuration Advanced Configuration Header Error LA FPGA Header Error Q FPGA Data Error Q Header CRC in Header FFFFFFFF Header CRC Calculated 7F1CDCE2 Configuration Data Error FPGA Header Error FPGA Data Error Data CRC in Header FFFFFFFF Data CRC Calculated FFFFFFFF Software Header Error Software Data Error Verify FPGA DDR Memory Error SSRAM Memory Error 00000000 Bootloader Jumper Select firmware file MAC Address 00 50 c2 97 54 ed Serial Number 0000001261 Bootloader Revision 0 1 0 12 A60 Jumpers TER Baseboard ID 0x881 Baseboard Jumpers 0x0 Failure Code 0 Figure 31 A60 recovery screen Red LED indications for the FPGA or Software show where the corrupted code is 4 Unzip the firmware release that you w
59. ys Keyswitch for selection of normal and diagnostic operating modes On board processors and buffer memory that extend the data collection capability of connected devices Processor watchdog protection Various host software options and scripting languages for system automation A560 User Manual A560 UM 150413 Page 11 of 67 PSI System Controls and Diagnostics 8 Specification Processors Ethernet processor NIOS II f 110 MHz OT eee Memory 32 MB of 32b x 110 MHz RAM for Ethernet processor 16 MB flash memory for Ethernet processor 1 MB 32b x 50 MHz RAM shared memory Operating system uCLinux 2 6 with high speed FPU instruction block in Ethernet processor Embedded C deterministic with high speed FPU instruction block 1n fiber optic loop processor Ethernet Fully transformer isolated Auto negotiation 1000 100 10 Mbps MDIX capability TCP IP and UDP Static or DHCP IP4 address assignment nii BENE ports Ten loop ports each a transmitter receiver pair rear panel re Ie to fifteen devices per port in input 24V 2V DC 800 mA max 500 mA typical Fused with 1 1A PTC fuse ld LCD navigation joystick Operating mode keyswitch Rear panel processor reset button Indicators Front panel 40 char x 2 line backlit LCD Front panel red LED keyswitch setting Eight green status LCDs read panel Case 1U stainless steel case with AI alloy front panel Protection rating The case is designed to rating IP
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