The GimbalCom MS2020 system controller is designed to perform the following functions:

Monitor the status of equipment or elements of a system.

Accept analogue inputs from external equipment.

Display status information, and the state of the analogue inputs.

Control the clean contact outputs to operate external equipment.

React to any specific system state, or change of state, in a controller and predefined manner.

The unit communicates via an Ethernet connection and will send an e-mail in the event of specific conditions.

The unit can be monitored & controller remotely using a Web browser.

The system contains redundant circuitry for all power supply functions and monitors its own internal state.

MS2020 Description

The MS2020 system controller is housed within a 4U, 19-inch rack mounted chassis and contains all components needed for the monitoring and control of the external system equipment (with the exception of the power supplies for LNB power and switch operation). The internal circuitry has four sub-modules each is considered separately.

The four internal sub-systems are: power supply and distribution components; micro-processor and associated hardware; the interface module which monitors signals from the interface PCBs and controls the high power outputs; and the Interface PCBs which provide signal conditioning, filtering and buffering to the outside equipment.

     The Unit power supply.

The unit power supplies are in redundant configuration.  Two 300W switch mode power supplies are provided and are ‘hot swappable’ both being capable of powering the unit.

The power supplies provide audible and visual indication of failure and their output ‘crowbars’ on overload. The summary status of the power block is monitored internally by the processor, which will report any failure

The unit has two IEC mains inputs whilst the ‘power block’ has one input. Where two feeds are available the IEC on the power block takes precedence but upon failure of this supply, the secondary supply is switched to the block. During the mains switching process the internal supplies are maintained by the capacity of the supply output circuitry and of the unit boards.

   Processor.

The microprocessor components are housed within the front section of the unit. The system being controller-monitored is depicted on the VGA LCD built into the front panel. Control of the system configuration and mode of operation is performed via the built in keypad.

Additional changes to the MS2020 set-up are performed using a keyboard interface located behind the input filter louvers. These should only be necessary if the MS2020 is re-deployed or software updated.

The processor also controls the 16 high current relays, located on the interface module, to operate external switches or units. This is done using a serial data connection between the interface module and processor board.

The process operating system is Linux and program software is written in C++.

A hardware watchdog timer limits any affects of a processor failure.

A visual and audible alarm will be generated in the event of an internal system failure.

Operation and features of the software are described in section 4 of this manual.

     Internal Printed Circuit Boards.

The system interface PCBs consist of three types; the PSU PCB which provides power for the reservoir capacitors to facilitate switching operations and system LNBs. The reference voltages for the digital and analogue inputs, visual indication of the state of the on board regulators and accepts the alarm inputs from external equipment are also via the MS2020-P31 Power supply PCBs.

The PSU PCBs also provide visual and clean contact status indications of the unit internal alarms and a system summary alarm.

The interface PCBs are designed to protect each of the elements within the system from faults on another. They provide voltage backups; input conditioning and filtering; and buffering for reference voltages and control voltages. The LNB power outputs are also protected against short circuits by an inline 1A fuse.

The receive interface PCBs provide three 21 to 18V outputs to power the LNA/LNB modules and the monitoring and control of two waveguide or coaxial switches. The LNA power is provided via an in line resistor, the voltage at either end of the resistor, are conditioned on the PCBs, and monitored. The processor calculates the actual current taken by the LNA.

These calculated currents are compared against a high and low level alarm settings entered to identify alarm conditions.

The PCC also provide the interface connector to the receive switches, providing drive and return operating signals and the position tellbacks from the switch.

Each PCB is capable of monitoring three LNB currents and interfacing with two waveguide/coaxial switches.

The transmit interface PCBs 'accept' three alarm inputs, these are wired internally from the SSPA/HPA interface connectors, mounted on the rear panel. The boards also monitor and control two waveguide or coaxial switches. Each PCB can monitor upto three SSPA/HPA’s and control two switches.

On the transmit switch interfaces there are two sets of tellback contacts, one is used to monitor the switch position and report locally and remotely, one is used to mute relevant SSPA/HPA’s during switch transition. Mute control is routed through the SSPA/HPA interface connector on the rear panel.

  Interface Module

The interface module accepts the inputs from the interface PCBs, and provides numerical values for each, to the processor. The communication between processor and interface module is via a serial interface internal to the MS2020.

The serial interface from the microprocessor, also controls the sixteen high current relays used to operate any switches. The switching power is routed from the power supply PCB’s via the reservoir capacitors, interface module and to the interface PCBs.

Operation

     Local operation

Local operation indicates that the MS2020 front panel is used to control the system. The built in VGA and keypad are used to adjust the ‘system configuration’ or ‘mode’ of operation.

Simple roll-down/up menus are used and the cursor keys provide navigation around the screen. The “Enter” and “Cancel” keys are used to change menu levels.

Error messages provide the operator with warnings or prompts if the action requested will compromise unit operation or are not allowed under the current mode of operation.

The top-level menu shows, from left to right, the designations for the sub-systems under control, the designation for the units that make up the sub-systems; the unit’s redundancy state; their traffic state, and their reported status.

          The menu bar at the base of the display provides the monitor and control options.

          The options and implications for the ‘redundancy state’ selections are:

Redundant     – This is used to indicate that a standby unit is ready to be used in place of an on line unit.

Auto             - Indicates an on line unit will be automatically backed up upon the event of a failure. Warnings will be given and e-mails sent in the event of a failure.

Manual          - An on line unit will be not be backed up upon the event of a failure. Warnings will be given and e-mails sent in the event of a failure.

Maintenance  - This state inhibits all alarms relating to the unit, if maintenance work is proceeding and regular alarms would be produced this mode will ignore them. No warnings or e-mails are sent.

Not fitted      - This mode ignores all alarm inputs and switch tellbacks associated with the units. It is designed for systems which are initially part populated, and to which extra chains will be added.

  Remote Operation.

Remote monitoring and control of the MS2020 is possible using the 10/100MHz Ethernet connection and a Web browser. All of the monitoring features available locally, and many of the control features, are available to the remote terminal.

  Customer setting and adjustments.

The unit has two levels of customer adjustment and control. The normal operation of the unit has no pass wording and allows the system configuration and mode to be changed on a unit by unit basis. Alarm levels and windows can be adjusted as required.

The second level is for the engineering manager, this allows control of internal settings and arrangements to be modified.

Software Operation and features

  Terminology

The terminology used to refer to the parts of a redundant system can vary considerably.  For the purposes of the MS-2020 controller, the following terms are used:

     Menus

The software is operated by means of menus that stay along the bottom of the screen, or pop-up in the centre to offer a choice of actions.  Menus are navigated by using the keypad to the right of the front panel.  The left and right arrow keys can be used to move the highlighted bar.  The OK key selects the currently highlighted option.  Some menus open sub-menus as either a pop-up or on a different screen.  A sub-menu can be exited by pressing the CANCEL key.

Some menu options will highlight items in an on-screen table.  These work in the same way as a normal menu, and can be navigated using the arrow keypad and the OK and CANCEL keys.

Pop-up menus appear when the system needs confirmation of an action or event, for instance when selecting a potentially dangerous option or when a request to switch to remote mode is received.  Most pop-up menus require either the OK or CANCEL button to be pressed in response to the message.  When a pop-up menu is on the screen, the operator can perform no other action until OK or CANCEL is pressed.  Some pop-up menus will override any other menu on the screen.

  The Top-Level Menu

The top-level menu is at the bottom of the screen when the top-level display is activated.  This is the default view when the MS-2020 unit is first powered up, and at any time when no other operation is being performed.  The options available from each menu item are outlined below.

This option leads to a new pop-up menu that allows units to be backed-up and restored, and allows the control mode of each unit to be changed.

   Control Mode

When you select the Control Mode menu item, the Control Mode column of the top-level display is highlighted.  The up and down arrow keys may be used to select a unit.  The OK button will cause a further pop-up menu to be displayed, that allows one of the four control modes to be selected, as detailed in section [** INSERT CROSS-REFERENCE HERE **].  Once the required control mode has been selected, press the OK button to change the unit’s mode.  To exit from the Control Mode pop-up menu without making any changes press the CANCEL button.  To return to the top-level menu, press the CANCEL button again.

    Backup

To back-up a unit, select this option.  The Status column of the top-level display will become highlighted.  Select the required unit, then press the OK button to back it up.  To return to the top-level menu, press the CANCEL button.

    Restore

To restore a unit, select this option and proceed as for Backup above.

    Restore All

This option will attempt to restore all healthy units within the system.  This may not always be successful, depending on the system state.

This option leads to a new screen that gives detailed information about a unit, and allows some of its details to be altered.

When this option is selected, the Unit Name column in the top-level display will be highlighted.  Select the required unit and press the OK button, or press the CANCEL button to return to the top-level menu.

    The Unit Details Screen

The name of the currently selected unit is displayed at the top-left of the screen.  Below this, a table shows the name of up to four parameters that are associated with the unit, or NULL where a parameter has not been configured.  To see further information and options about a parameter, highlight its name and press the OK button.  This table also shows information about the unit’s mode, status and health.  These cannot be altered from this screen.  To return to the top-level display, press the CANCEL button.

    The Parameter Details Screen

If a parameter is selected and the OK button is pressed, a further table will be displayed showing this parameter’s details.  The minimum and maximum values considered to be ‘good’ can be altered, and the option to log all data can be set.  To change a value, highlight the required value using the arrow keys and press the OK

button.  Press the CANCEL button to return to the previous value.  Press the CANCEL button again to return to the Unit Details screen.

This option will acknowledge all current alarms.  Any flashing alarms will become a steady red colour.  If any further alarm conditions occur, the alarm will restart, but alarms that have been previously

acknowledged will not start to flash again, to allow the operator to quickly see new faults.

This option allows additional display modes to be selected:

    Parameter Values

This shows a table of all the configured parameters, and their current values from the A-D converter.  This is useful for troubleshooting and diagnostic purposes.

    Log Files

This allows log files to be read on-screen, to allow the operator to see a history of events in the system when a fault occurs.

This option allows the altering of settings that relate directly to the MS-2020 controller.  Selecting this option changes the display to a new menu entitled ‘MS-2020 Config’ with the following options:

    Logger Menu

This moves to another menu with options for the event logger.  To change a value, highlight the required value using the arrow keys and press the OK button.  Press the CANCEL button to return to the previous value.  Press the CANCEL button again to return to the System menu.

    Network Settings

This moves to another menu with network settings.  To change a value, highlight the required value using the arrow keys and press the OK button.  Press the CANCEL button to return to the previous value.  Press the CANCEL button again to return to the System menu.

    Save System State

This option will save the current state of the system, which then becomes the default state.  This is most useful when the ‘window’ of a parameter has been changed, and the new values need to become permanent.

    Reset Controller

          This options resets the MS-2020 to its initial switch-on state.

    Shut Down System

Shuts the MS-2020 software down, ready for maintenance or relocation.

    Development

This menu is password protected, and will normally only be available to Gimbalcom engineers or suppliers.  Options on this menu are potentially dangerous if used in an installed system and are intended for pre-installation testing.

     Log Files

The MS-2020 keeps log files that record events that have taken place within the system.  Log entries always start with a date and time, followed by a plain English message of some sort.  There are three files: actions, sensors and errors.

Whenever the MS-2020 makes some sort of change to the redundancy chains that it is controlling, a record is made in the Actions log file.  If an alarm status occurs and there is no redundant unit available to back-up the alarming unit, a log entry will still be made explaining why the unit could not be backed up.

If the ‘Log’ option of a parameter has been set,its value will be recorded in this file at predetermined time intervals.

Entries are only made to this log if an internal error has occurred in the MS-2020.  This file will normally be used by GimbalCom engineers in the event of a fault with the MS-2020.

Log files can be viewed using the Display option on the top-level menu.  Log files can also be downloaded across a network and viewed on a desktop PC or via the Web interface.

The MS-2020 will continue adding entries to log files indefinitely.  Log files should be periodically downloaded and cleared, or simply deleted outright.  [** ADD MORE HERE **].

    Remote Access

To configure remote access, the MS-2020 unit must be connected to a 10/100 Ethernet network and given a valid IP address and netmask.].  If Microsoft Windows computers are to be used to access log files and update software on the MS-2020 then a Workgroup name must also be given.

To set up networking:

determine an IP address that may be used (each device on a network must have a unique IP address)

connect the external keyboard to the MS-2020 front panel

select System from the top-level menu

select Networking

enter an IP address, netmask, and Windows workgroup if required (to enter values, highlight the required value using the arrow keys and press the OK button; use OK to confirm the new value or CANCEL to return to the old value)

highlight the Apply option then press the OK button

The ‘Host Name’ (that is, the name of the computer that shows up within Windows) will be MS-2020-XX where XX is the number of your unit.  The MS-2020 will be visible as a standard computer within the Workgroup that it has been given.  It will often take several minutes for a newly configured machine to appear – if it does not appear then typing ‘\\MS-2020-XX’ into a Windows Explorer window will often work (replacing XX with the number of your unit, shown at the top-left corner of the top-level display).

    Viewing Log Files  

Once the MS-2020 has been located in Windows Explorer, there should be two folders visible: logs and upgrades.  The logs folder contains the log files as detailed above.  Logs can be viewed, downloaded and deleted from here (to download a log file, simply copy it as if it were any other file within Windows).  The upgrades folder is used for software upgrades to the MS-2020.

To control the MS-2020 remotely, simply type the configured IP address into the web browser (commonly ‘Internet Explorer’) of any computer that has access to the same Ethernet network as the MS-2020.  (For example, if the IP address configured is 192.168.120.123, enter ‘http://192.168.120.123/’ into the web browser).  The Web Interface should work with any modern web browser (i.e. Internet Explorer 4.0 or greater, Netscape Navigator 4.0 or greater, Opera, Mozilla etc.)

The Initial Display

When the Web Interface is first started, a welcome screen will be displayed.  From here, options can be selected from the menus at the bottom of the screen.

Viewing Logs

To view logs, click the logs link at the bottom of the page.  The three log files can be viewed by clicking on their name.  To download a log file, use your web browser’s save function (often SHIFT+click).

To start remote control, click the remote control link at the bottom of the initial Web Interface screen.  There will be a short delay as the MS-2020 displays a message on the front panel screen to allow a local operator to override remote control.  If remote control is overridden, an error screen will be shown; if remote control is not overridden then a display similar to the front panel screen top-level display will be presented.  You will also not be able to start remote control if another computer is already controlling the MS-2020 remotely. 

If remote control is started, you will be given remote lock, which means that the front panel controls will not function, and no other computer may attempt to start remote control.  Remote lock times out and returns control to the front panel after a few minutes.

    Operations

The display presented is similar, but not identical to the top-level display.  Alarm indicators do not flash, but are a constant red colour.

To perform an operation on a unit:

select a unit by clicking on one of the small circular option buttons to the right of each column – only one unit may be selected at a time

select an operation from the list at the bottom of the screen

click the proceed button

One of several things may then happen:

the operation is immediately successful, and a screen is presented with a green border, before returning to the top-level display

the operation makes an important change to the system and required confirmation – a screen is presented with OK and CANCEL buttons

the operation fails – a screen is presented explaining the failure before returning to the top-level display.

    Ending Remote Lock

To end remote lock and return control to the front panel, click the End Remote Lock link at the bottom f the screen.

Maintenance

Internal fans moving air from the front to the back of the unit provide cooling. A filtered air inlet provides air via the front panel.

The filter can be accessed by pulling the pop-clips to release the louvered cover.

The filter should be removed & cleaned no longer than every 3 months of operation.

The Log files are held locally on the hard disc, it is recommended for ease of data identification that these be downloaded each month or quarter and a new log started.

This operation can be performed locally using the floppy disc to save the data or via the Ethernet connection. Old logs on the MS2020 should be deleted or over-written to prevent the hard disc space filling up and causing problems.

It is estimated that the hard disc space available for logs will support a number of  years.

Fault finding and wiring.

The MS2020 controller has a high level of redundancy for the modules. The emphasis is on retaining service whist maintenance is performed, however care should always be taken when working on a powered unit.

There are three separate supplies and five inputs into the controller. Even if it is isolated from the mains, Voltages can still be present within the unit. Extreme caution is therefore required when faultfinding.

The unit has the following supplies:

               X1      IEC 1            240V AC

               X2      IEC 2            240V AC

               J3       3 pin inlet      115V AC

               X4      XLR              +24V DC

               X5      XLR              +24V DC

Internal alarms will be generated for the following problems:

Mains PSU failure –

A monitoring circuit within the power supply unit will produce a visual and audible warning both to the front on the unit (the LEDs behind the filter cover) and to the rear on the faulty PSU unit. The fault will also be registered with the interface module and via the front panel and remote monitoring system.

The PSU modules are ‘hot swappable’, both being capable of powering the MS2020 alone.

If the MS2020 is operating or switched off, power will be supplied to the LNA/B systems via the redundancy +24V units.

The three power supply boards connect to both +24V inputs from the redundant unit and diode combine them. These PCBs provide volts to the reservoir capacitors used to provide power for switching operations. The +24V supplies also provide power for the LNA/Bs.

Each PCB has a primary (+21V) regulator and a secondary (+18V) regulator for the LNA/Bs power. The status of each of these regulators is indicated by the LEDs located on the top edge of the boards. Failure of any of the regulators (on any of the PSU boards) will result in the relevant LED extinguishing and the monitoring system within the unit producing a visual and audible alarm both locally and a remote visual indication.

Internal circuitry within the unit allows any one of the PCBs to be removed without affecting the system operation.

MS2020-P22 Receive boards provide power and monitoring for the LNA/Bs.

To protect other systems and power supplies, a 1A fuse is fitted inline with the LNA/B. In the event that the fuse is ‘blown’ the monitored voltage at the PCB output will reduce to zero and ‘current’ alarm will result. This situation will be indicated locally by a visual and audible alarm.

The MS2020 ‘Display’ screen can be used to check the current values. The LNA/B supply voltage can be monitored at the terminal blocks on the receive interface boards. This should be between 16 and 20 volts.

Replacement of a ‘blown’ fuse can be performed without affecting the traffic on the other LNA/Bs in the group. Careful withdrawal of the applicable PCB can be performed whilst the board is ‘live’ * Warning – When this is performed on PCB 5 the 115V AC supply must be isolated for safety. The 115V is not present on the PCB unless the switching operation is being performed, however to ensure operator safety it is recommended to disconnect the 115V supply from X3.

The transmit and receive interface boards also provide the MS2020 interface for the switch control and monitoring. Signals pass from the reservoir capacitors to the control relays and then though the interface board to the system. The switch control voltages are 1 second pulses of +24V and can be monitored on the terminal block situated behind the 9 way D type switch interface connectors.

Both transmit and receive PCBs will operate if they are removed from the chassis (care must be taken to prevent them shorting onto other equipment).

Whenever a PCB is removed the units monitored and controlled by it should always be put into maintenance mode to prevent spurious switching and fault reporting.