LASER INTERFEROMETER GRAVITATIONAL WAVE OBSERVATORY

LIGO Laboratory / LIGO Scientific Collaboration

LIGO-E1900185-v2 Advanced LIGO 6/1/2020

TwinCAT EPICS IOC (tcIoc) User Guide

Daniel Sigg

Distribution of this document:

LIGO Scientific Collaboration

This is an internal working note

of the LIGO Laboratory.

California Institute of Technology Massachusetts Institute of Technology

LIGO Project – MS 18-34 LIGO Project – NW22-295
1200 E. California Blvd. 185 Albany St
Pasadena, CA 91125 Cambridge, MA 02139
Phone (626) 395-2129 Phone (617) 253-4824
Fax (626) 304-9834 Fax (617) 253-7014
E-mail: info@ligo.caltech.edu E-mail: info@ligo.mit.edu

LIGO Hanford Observatory LIGO Livingston Observatory

P.O. Box 159 P.O. Box 940
Richland WA 99352 Livingston, LA 70754
Phone 509-372-8106 Phone 225-686-3100
Fax 509-372-8137 Fax 225-686-7189
http://www.ligo.caltech.edu/

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Table of Contents
1 Introduction...................................................................................................3
2 IOC Commands.............................................................................................3
2.1 EPICS Initialization............................................................................................3
2.2 Scan Rate...........................................................................................................4
2.3 Loading Records...............................................................................................4
2.4 Alias and Replacement Rules..........................................................................5
2.5 Generating Listings..........................................................................................5
2.6 Information Records.........................................................................................5
2.7 Generating Macros............................................................................................6
3 TwinCAT EPICS Options..............................................................................8
4 OPC Specification.......................................................................................10
4.1 OPC Access.....................................................................................................12
4.2 OPC Properties................................................................................................12
4.3 Automatic Type Support................................................................................14
4.4 Enumerated Types..........................................................................................14
4.5 Array Variables................................................................................................15

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1 Introduction
The TwinCAT EPICS IOC, tcIoc, is an interface between the TwinCAT automation software
and the EPICS channel access. It makes TwinCAT variables available to the EPICS system using
an annotation mechanism similar to the TwinCAT OPC server. The exported variables of one or
multiple TwinCAT PLCs are scanned at a fixed rate using the TwinCAT ADS communication
library. A memory pool is setup in the IOC which mirrors the variable value in the TwinCAT
PLCs. On the EPICS side a device driver has been written for a “tcat” device that interfaces this
memory pool and makes all variables available using channel access. Special care was taken to
map EPICS output channels to TwinCAT variables that are both readable and writeable. EPICS
input channels are mapped to TwinCAT read only variables. Write only variables are not
supported.
In the current TwinCAT EPICS IOC implementation, the exported variables have to be declared
as global symbols. They can be of complex types such as structures and arrays—even structures
of structures. Since EPICS doesn’t support complex types, complex types are expanded down to
the simple types, which are then exported each as an EPICS database record. Floating point types
are mapped to ai/ao records, integer types to longin/longout records, character strings to
stringin/stringout records, and Boolean types to bi/bo records. Enumerated types are mapped to
mbbi/mbbo records, if the numerical representation lies within 0 to 15. Otherwise, they map to
longin/longout records as well. EPICS only supports short strings, so TwinCAT string values
that are larger than 40 characters are truncated.
EPICS also has limitation on the length of channels names. The current limitation is 56
characters maximum. Since the EPICS channel names are typically derived from the full
TwinCAT variable name, one has to be careful to stay within this limit. Deep structures of
structures can exceed this limit more easily, since each element name is appended to the base
variable name.
If a TwinCAT PLC is halted, the data exchange will stop and all EPICS variables are set to
invalid. If the TwinCAT PLC is restarted, the data exchange will be reinitialized and the EPICS
variables become valid again. The tcIoc is periodically checking the TwinCAT configuration. If
it has changed, e.g., after a recompiling and reloading, the data exchange will also stop. Since the
tcIoc cannot alter the EPICS database, it has to be terminated and restarted to load the new
configuration.

2 IOC Commands
The TwinCAT EPICS IOC looks like a normal IOC, but supports an extra command set to
configure the TwinCAT interface. A typical tcIoc configuration file is listed in Table 1. The last
command in a tcIoc configuration file should be the “iocInit()” command to start the EPICS
server.

2.1 EPICS Initialization

The first three commands in Table 1 initialize the EPICS system. The first line loads the
“tCat.dbd” database file which defines the TwinCAT database records. The second line registers

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the TwinCAT specific device driver commands, and the third line increases the callback queue
size, which may be needed for large databases.

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dbLoadDatabase("C:\SlowControls\tcIoc\tCat.dbd",0,0)
tCat_registerRecordDeviceDriver(pdbbase)
callbackSetQueueSize(50000)

tcSetScanRate(10, 5)
tcSetAlias("C1PLC1", "IFO=H1,END=X")
tcGenerateList("C:\SlowControls\Target\PLC1.opc.txt","-l -rn -yi -cp")
tcGenerateList("C:\SlowControls\Target\PLC1.chn.txt","-l")
tcGenerateList("C:\SlowControls\Target\PLC1.req","-lb")
tcGenerateMacros("C:\SlowControls\Target\ADL")
tcInfoPrefix(".\${IFO}.Sys.\${ALIAS}.info")
tcLoadRecords ("C:\SlowControls\Target\PLC1.tpy")

iocInit()

Table 1: Typical configuration file for the TwinCAT EPICS IOC.

2.2 Scan Rate

The command “tcScanRate” sets the scan rate for the TwinCAT PLC. The first argument is the
scan rate in milli seconds for the read or write scanners reading and writing TwinCAT variables.
The second number is a multiplier which describes the slow down for updating the EPICS read-
only channels. The update rate for read/write channels is the same as the TwinCAT scan rate. In
Table 1, “tcSetScanRate(10,5)” yields a 10ms TwinCAT update rate, and a 50ms EPICS update
rate for read-only channels. EPICS writes are always propagated to TwinCAT at the next write
update cycle.

2.3 Loading Records

TwinCAT2 will generate a “.tpy” file, whenever a PLC is compiled. This tpy file is an XML
documents describing the PLC configuration. It lists all used types and the variables. This file is
also available in TwinCAT3, but is not generated automatically and has to be enabled in the
TwinCAT project. After loading a tpy file using the “tcLoadRecords” command, the tcIoc will
go through all exported TwinCAT variables, build an internal memory pool and generated an
EPICS database file with the same name, but the extension “.db”. Next, it will load the newly
generated EPICS database using the standard EPICS load database command. When EPICS
loads a database record, it will call the “tcat” device driver, which in turn will link the record
back to the memory pool.
The tcIoc watches the modification time of the tpy file to determine, if the TwinCAT
configuration has changed. TwinCAT read and write cycles will stop, if the tpy has changed.
The second argument to the “tcLoadRecords” command is an optional set of arguments that are
described in Section 3. This command must come after setting the alias and replacement rules,
after setting the info prefix, and after setting up listings and macro processing.

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2.4 Alias and Replacement Rules

The command “tcAlias” is used to set the alias name for a PLC as well as define replacement
rules that are used in the channel name generation. The first argument is simply the alias name,
whereas the second argument is a string assigning values to substitution variables, separated by
commas. The alias defines an implicit replacement rule of the form “ALIAS=alias name”.
When specifying the OPC properties associated with a TwinCAT variable or structure element,
see Section 4, it is possible to define an alternate name which can use substitution variable. For
example, specifying “${Ifo}End${End}” uses the substitution variables, “Ifo” and “End”, which
will lead to “H1EndX” after the replacement rules in Table 1 are applied.
One place to be careful is a replacement rule for a global variable. TwinCAT2 will silently
prepend a dot to all global variables, whereas TwinCAT3 will prepend a namespace designator
and a dot. Typically, this leading dot and namespace designator are unwanted, and the TwinCAT
EPICS IOC will by default remove any letters up to and including the first dot. Since
replacement rules are applied globally after any alias substitution, a top level alias name will also
have its leading dot and namespace designator removed. If it doesn’t have a leading dot, it may
be misinterpreted as a namespace designator. Therefore, if a global variable uses an alias name, it
probably needs to start with an explicit dot, and possibly a namespace.

2.5 Generating Listings

Channel listing can be generated using the “tcGenerateList” command. The first argument is the
listing file name, while the second argument a set of options that are described in Section 3.

2.6 Information Records

The TwinCAT EPICS IOC supports a set of database records that give information about the
PLC configuration within the IOC and are not linked to TwinCAT variables. Supported info
records are listed in Table 2.
Information records are enabled by specifying a prefix using the “tcInfoPrefix”. The prefix is
prepended to the information records with a dot in between. The same conversion and
replacement rules apply as with TwinCAT variables. So, the prefix probably needs to start with
an explicit dot.
The “cb.queue” information records report the size of the callback ring buffer size, as well as the
used and free entries. It requires a patch of the EPICS libraries to work. Consult the
documentation of “EpicsInterface::get_callback_queue_size” function.

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Information Description Type

name Name of PLC STRING
alias Alias name STRING
active Running state of PLC (ONLINE/OFFLINE) BOOL
state AMS state of PLC ENUM
statestr AMS state of PLC STRING
timestamp.str PLC time stamp (format 2019-1-31 09:13:56) STRING
timestamp.x x is year, month, day, hour, minute or second INT
rate.read Period of read scanner in ms INT
rate.write Period of write scanner in ms INT
rate.update Period of update scanner in ms INT
records.num Number of records INT
tpy.filename Name of typ file STRING
tpy.valid Validity of tpy file (VALID/INVALID) BOOL
tpy.time.str Modifcation time of tpy file STRING
tpy.time.x x is year, month, day, hour, minute or second INT
ads.version ADS library version INT
ads.revision ADS library revision INT
ads.build ADS library build INT
ads.port ADS/AMS port of PLC INT
ads.netid.str ADS/AMS address of PLC STRING
ads.netid.b0..5 ADS/AMS address b0, b1, b2, b3, b4 and b5 INT
svn.local SVN local modifications (MODIFIED/COMMITTED) BOOL
svn.revision SVN revision if fully committed (zero otherwise) INT
svn.time.str SVN compile time STRING
cb.queue.size Size of EPICS callback queue INT
cb.queue.used Used entries in EPICS callback queue INT
cb.queue.free Free entries in EPICS callback queue INT

Table 2: Supported information records.

2.7 Generating Macros

Macros can be used to automatically generate user screens. The command “tcGenerateMacros”
with an argument pointing to a directory is used to enable macro generation.
Generating macros will create one file per structure which describes the structure elements. If a
structure contains an ErrorStruct of the form:

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TYPE ErrorStruct :
STRUCT
Flag: BOOL; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :1: OPC_PROP_RIGHTS)
(OPC_PROP[0101] :Error flag: Description)
(OPC_PROP[0106] :Error: ONAM)
(OPC_PROP[0107] :OK: ZNAM)
*)
Code: DWORD; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :1: OPC_PROP_RIGHTS)
(OPC_PROP[0101] :Bit endcoded error condition: Description)
*)
Msg: STRING; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :1: OPC_PROP_RIGHTS)
(OPC_PROP[0101] :Human readable error message: Description)
*)
END_STRUCT
END_TYPE;

It will also generate macros for error screens. For this to work properly, a global list needs to be
defined that contains all error messages. These error messages need to be defined in a global
constant of type ErrorMessagesArray. Example:

TYPE ErrorMessagesArray : ARRAY [1..32] OF STRING;

END_TYPE;

VAR_GLOBAL CONSTANT
ThermistorStruct_Errors: ErrorMessagesArray :=
(* 1 *) 'Thermistor resistance is too high',
(* 2 *) 'Thermistor resistance is too low',
(* 3 *) 'Thermistor data invalid',
(* 4 *) 'Thermistor measurement error';
END_VAR

The name of the constant string array has to reflect the name of the structure that contains the
error structure with the extension “_Errors” added. In TwinCAT2 this constant has to be linked
to a file with the name “ThermistorStruct_Errors.exp” with the option “Export before compile”
selected. This will guarantee that the automatic screen generator is able to assemble an error list
for each structure.

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3 TwinCAT EPICS Options

Variable names in TwinCAT are translated into EPICS channel names using conversion rules.
When generating a database file or a listing, a set of options specifying the conversion rules is
available. Options can be specified in either Windows or Unix style. Meaning, both /ea and -ea
will produce the same result.

Option Description
Channel Processing:
/eo (default) Only export variables which are marked by an OPC export directive in the tpy file
/ea Export all global variables regardless of the OPC settings in the tpy file
/ys (default) String variables are processed
/ns No string variables are processed
/pa (default) Process all types
/ps Process only simple types types, e.g., INT, BOOL, DWORD, etc.
/pc Process only complex types, e.g., STRUCT, ARRAY
Channel Name Conversion:
/rl (default) LIGO standard conversion rule
/rv LIGO rules for initial vacuum channel names (version 1.1)
/rd Replace dots with underscores in channel names
/rn Do not apply any special conversion rules
/cp Preserve case in EPICS channel names
/cu (default) Force upper case in EPICS channel names (default)
/cl Force lower case in EPICS channel names
/nd (default) Eliminate leading dot in channel name as well as all prior characters
/yd Leave leading dot in channel name as well as all prior characters
/yi Leave array indices in channel names
/ni Replace array brackets with a single leading underscore
/p 'name' Include a prefix of 'name' for every channel (defaults to no prefix)
Split File Support:
/nsio (default) Do not split database or listing by record type
/ysio Split database or listing into input only and input/ouput recrods
/sn ‘num’ Split database or listing into files with no more than 'num' records
/sn 0 (default) Does not split database or listing into multiple files

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Database Generation (depreciated):

/devopc (def.) Use OPC name in INPUT/OUTPUT field
/devtc Use TwinCAT name in INPUT/OUTPUT fields instead of OPC
List Generation:
/l (default) Generate a standard listing, name only
/ll Generate a long listing, name and opc parameters
/lb Generate an autoburt save/restore file
/li Generate a LIGO DAQ ini file
Macro Generation:
/ma (default) Generate a macro file for each structure describing fields and errors
/me Generate a macro file for each structure describing the error messages
/mf Generate a macro file for each structure describing all fields

Table 3: TwinCAT EPICS Options

The applicable options are as follows:

Available options Enforced options

Utility programs
tpyinfo channel processing
EpicsDbGen All (program depreciated)
tcIoc commands:
tcLoadRecords channel processing, channel name conversion -ps -nsio -sn 0 -devtc
tcGenerateList channel processing, channel name conversion, list -ps -nsio -sn 0
generation
tcGenerateMacros macro generation

Table 4: Applicable Options

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4 OPC Specification
We are using the TwinCAT OPC comments denoted by (*~ ... *) to make global variables
accessible to the OPC server. The opening bracket annotation needs to be on the same line as the
variable. OPC properties are used to describe additional database fields such as limits
(HOPR/LOPR), precision (PREC) and many more. These OPC properties are translated into
corresponding EPICS database fields. An extended example can be found in Table 5.

Individual tags such as the LaserType of the ALSLaserStruct will have the TwinCAT name
“H1.Als.X.Laser.LaserType”. The default EPICS channel name constructed from this tag will
then become “H1:ALS-X_LASER_LASERTYPE”, if the LIGO standard conversion option is
selected. Be aware that TwinCAT names are not case sensitive, whereas EPICS channel names
are case sensitive.

TYPE ALSLaserEnum : (
NPRO, (*NPRO*)
Diode, (*DIODE*)
Argon (*ARGON*)
};
END_TYPE; (*~
(OPC_PROP[8510] :NPRO: ZRST)
(OPC_PROP[8511] :DIODE: ONST)
(OPC_PROP[8512] :ARGON: TWST)
*)

TYPE ALSLaserStruct:
STRUCT
Error: ErrorStruct;
LaserType: ALSLaserEnum;
LaserDiodePowerMonitor: LREAL; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :1: OPC_PROP_RIGHTS)
(OPC_PROP[0100] :A: Unit/EGU)
(OPC_PROP[0101] :Laser diode 1 power monitor: Description/DESC)
(OPC_PROP[8500] :3: Display precision/PREC)
*)
LaserDiodePowerNominal: LREAL; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :3: OPC_PROP_RIGHTS)
(OPC_PROP[0100] :A: Unit)
(OPC_PROP[0101] :Laser diode power nominal: Description)
(OPC_PROP[8500] :3: Display precision)
*)
NoiseEaterRelay: BOOL; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :3: OPC_PROP_RIGHTS)

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(OPC_PROP[0101] :Noise Eater Relay: Description)

(OPC_PROP[0106] :On: ONAM)
(OPC_PROP[0107] :Off: ZNAM)
*)
CrystalTemperature: LREAL; (*~
(OPC :1: Make variable visible for OPC-Server)
(OPC_PROP[005] :3: OPC_PROP_RIGHTS)
(OPC_PROP[0100] :V: Unit)
(OPC_PROP[0101] :Crystal temperature: Description)
(OPC_PROP[0102] : 10: HOPR)
(OPC_PROP[0103] :-10: LOPR)
(OPC_PROP[8500] :7: Display precision)
*)
END_STRUCT
END_TYPE;

TYPE AlsEndStruct :
STRUCT
Laser: ALSLaserStruct;
VCO: LowNoiseVcoStruct;
PZT: ARRAY [1..2] OF PZTMirrorStruct;
…
END_STRUCT
END_TYPE;

TYPE AlsStruct :
STRUCT
End: AlsEndStruct; (*~
(OPC :1: visible)
(OPC_PROP[8620] :${END}: alias name)
*)
END_STRUCT
END_TYPE
…
TYPE IfoStruct:
STRUCT
Als: AlsStruct;
…
END_STRUCT
END_TYPE;

VAR_GLOBAL
IFO: IfoStruct; (*~
(OPC :1: visible)
(OPC_PROP[8620] :.${IFO}: alias name)
*)
END_VAR;

Table 5: Example TwinCAT global variable with OPC comments

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4.1 OPC Access

The global variable describing the interface structure of the interferometer is made accessible to
the OPC server by using the OPC comments. Meaning,

IFO: IfoStruct; (*~

(OPC :1: visible)
… *)

will make the entire IFO variable with all its sub elements visible through the OPC interface. In
turn, it can be interfaced by EPICS. The default behavior of a structure element is to be visible,
when the corresponding global variable is visible. However, if an OPC comment is added to a
structure element, the visibility has to be set explicitly again.

4.2 OPC Properties

OPC properties are used to further describe the external EPICS records. These properties have to
be attached to the last element in a hierarchical levels of structures. These are the elements with a
basic type like BOOL, INT, STRING or LREAL.
Only a subset of EPICS database fields are supported. In general, fields associated with
conversion and calculations are not supported, since all processing should be done within the
PLC program. The supported general properties are listed in the Table 6.
If a property is specified for a structure, it is used as the default value for all its elements. It can
be overwritten by each element below. NO_ALARM, MINOR and MAJOR are the allowed
alarm severity values. HIHI and LOLO alarms are assigned major severity, if they are defined;
whereas LOW and HIGH alarms are assigned minor severity, if they are defined. Custom fields
for alarm are currently not supported.
The alias property can be used, if a desired EPICS name clashes with a built-in TwinCAT name.
Employing substitution variables, it can also be used to configure names during tcIoc startup
based on the replacement rules.

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Property ID Description Record

5 Access control: 1 – read-only, 3- read/write all
100 EGU: Engineering units numeric
101 DESC: Description all
102 HOPR: High operations value numeric
103 LOPR: Low operation value numeric
104 DRVH: Maximum instrument range numeric
105 DRVL: Minimum instrument range numeric
106 ONAM: Label for closed (one) state binary
107 ZNAM: Label for open (zero) state binary
306 HYST: alarm deadband numeric
307 HIHI: hihi alarm level numeric
308 HIGH: high alarm level numeric
309 LOW: low alarm level numeric
310 LOLO: lolo alarm level numeric
8500 PREC: Display precision numeric
8510 to 8525 ZRST, ONST, ... FFST: Zero string, one string, ... fifteen string mb binary
8600 EPICS data type (bi, bo, ai, ao, longin, longout, stringin, stringout, all
mbbi, mbbo, mbbiDirect, and mbboDirect)
8601 Input or output: overwrites the default behavior all
8602 TSE: Time stamp; default is -2 all
8603 PINI: default 1 for input and 0 for output records all
8604 DTYP: default is opc; can be overwritten with opcRaw all
8610 Default OPC server name; default is opc top level
8611 TwinCAT runtime name including ads routing info and port top level
8620 Alias for structure item or top level symbol top & items
8700 OSV: one alarm severity binary
8701 ZSV: zero alarm severity binary
8702 COSV: change of state alarm severity (mb) binary
8703 UNSV: unknown state alarm severity mb binary
8710 to 8725 ZRSV, ONSV, … FFSV: zero, one, … fifteen state alarm severity mb binary
8727 to 8730 HHSV, HSV, LSV and LLSV analog
8800 to 8999 FIELD: Any database field can be specified in the comment don’t use
string; does not perform any checks; use only when truly
desperate

Table 6: Supported OPC properties.

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4.3 Automatic Type Support

By default all variables that are read-only will be represented by EPICS input records, whereas
all variables that have read/write access will be represented by EPICS output records. This
behavior can be overwritten, but there should never be a reason to.
The table below shows the default EPICS type selected for the database depending on the
TwinCAT datatype.

EPICS TwinCAT
longin/longout SINT, INT, DINT, LINT, USINT, UINT, UDINT, ULINT, BYTE, WORD, DWORD,
LWORD
bi/bo BOOL
mbbi/mbbo Enumerated data type with 16 or fewer labels
stringin/stringout STRING
ai/ao REAL, LREAL, any other

Table 7: Automatic type support.

4.4 Enumerated Types

An enumerated type will be converted into a multi-bit binary record, if there are 16 or fewer
labels and if all numeric representations are between 0 and 15. There is no conversion possible.
The numeric value of the enum type has to be the same as its EPICS representation, i.e., the zero
value will be set to 0, etc. The string values of the multi-bit binary record are automatically set to
the labels of the enumerated type.
Since enum labels need to be unique in TwinCAT2, one usually has to add a prefix to guarantee
that there are no name conflicts. This leads to somewhat cumbersome names in EPICS. It is
therefore possible to specify the EPICS enum labels differently. Example:

TYPE IfoIdEnum : (IfoH1, IfoL1, IfoH2, IfoT1, IfoI1);

END_TYPE (*~
(OPC_PROP[8510] :H1: ZRST)
(OPC_PROP[8511] :L1: ONST)
(OPC_PROP[8512] :H2: TWST)
(OPC_PROP[8513] :T1: THST)
(OPC_PROP[8514] :I1: FRST)
*)

This leads to EPICS labels of the form H1, L1, etc. rather than the default IfoH1, IfoL1, etc.
TwinCAT3 no longer requires enum labels to be unique, so they can be defined exactly as they
will be seen in EPICS. Unfortunately, the OPC support in TwinCAT3 is broken for enumerated
types, and one has to revert to normal comments after each tag; see Table 5 for an example.

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4.5 Array Variables

Array variables are supported by TwinCAT and can be exported through OPC as well. They will
be accessible through EPICS, but require an extension to the LIGO channel naming convention.
For example, if the structure “L1.Io.Wfs1” is of type WfsStruct and contains the members:

TYPE DemodComplex:
STRUCT
I: LREAL;
Q: LREAL;
END_STUCT
END_TYPE;

TYPE WfsStruct:
STRUCT
Gain: ARRAY [1..4] OF LREAL;
Rotation: ARRAY [1..4,1..4] OF LREAL;
Signal: ARRAY [1..4] OF DemodComplex;
END_STUCT
END_TYPE;

The corresponding OPC and EPICS variables are (with m and n ranging from 1 to 4):

Type TwinCAT name EPICS name (LIGO standard)

LREAL L1.Io.Wfs1.Gain[1] L1:IO-WFS1_GAIN_1
LREAL L1.Io.Wfs1.Rotation[1][2] L1:IO-WFS1_ROTATION_1_2
LREAL L1.Io.Wfs1.Signal[3].I L1:IO-WFS1_SIGNAL_3_I
LREAL L1.Io.Wfs1.Signal[3].Q L1:IO-WFS1_SIGNAL_3_Q

Table 8: Array variables in TwinCAT and EPICS.

Each individual array index will be exported as separate EPICS channel.

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