io-commissioning-kit

I/O-list-driven commissioning toolkit for a simulated instrumentation rack of a laser amplifier test bench. By Pavan Yadava Annappa.

Everything on this page is simulated. The rack, the field devices, the wiring faults and the OPC UA server are a local Python simulation. No real hardware, PLC or plant data is involved. The interlock logic is a test harness, not a safety function.

Documentation chain: I/O list (YAML) → lint → cable schedule, interface description, loop-check procedure → loop check over OPC UA → commissioning record → issue log.

I/O list (38 points, revision C)

Tag	Description	Signal	Range / normal	Channel	Cable	JB	Cabinet
FT-101	Coolant flow, amplifier head circuit	AI_4_20mA	0 .. 20 L/min	A1-AI1.1	W-FT-101	JB-1	A1-X2:1 A1-X2:2
FT-102	Coolant flow, diode pump modules	AI_4_20mA	0 .. 40 L/min	A1-AI1.2	W-FT-102	JB-1	A1-X2:3 A1-X2:4
PT-101	Coolant supply pressure	AI_4_20mA	0 .. 10 bar	A1-AI1.3	W-PT-101	JB-1	A1-X2:5 A1-X2:6
LT-101	Coolant tank level	AI_4_20mA	0 .. 100 %	A1-AI1.4	W-LT-101	JB-1	A1-X2:7 A1-X2:8
TT-101	Coolant supply temperature	AI_RTD	0 .. 50 degC	A1-RT1.1	W-TT-101	JB-1	A1-X2:9 A1-X2:10 A1-X2:11
TT-102	Coolant return temperature	AI_RTD	0 .. 50 degC	A1-RT1.2	W-TT-102	JB-1	A1-X2:12 A1-X2:13 A1-X2:14
TT-103	Amplifier head body temperature	AI_RTD	0 .. 100 degC	A1-RT1.3	W-TT-103	JB-1	A1-X2:15 A1-X2:16 A1-X2:17
CH-101-RUN	Chiller running	DI	normal TRUE	A1-DI1.1	W-CH-101-RUN	JB-1	A1-X2:18 A1-X2:19
CH-101-FLT	Chiller healthy (opens on fault)	DI	normal TRUE	A1-DI1.2	W-CH-101-FLT	JB-1	A1-X2:20 A1-X2:21
CH-101-EN	Chiller remote start	DO	normal FALSE	A1-DO1.1	W-CH-101-EN	JB-1	A1-X2:22 A1-X2:23
PT-201	Vacuum, spatial filter tube	AI_0_10V	1e-08 .. 100 mbar	A1-AV1.1	W-PT-201	JB-2	A1-X2:24 A1-X2:25 A1-X2:26
PT-202	Vacuum, forevacuum line	AI_0_10V	0.001 .. 1000 mbar	A1-AV1.2	W-PT-202	JB-2	A1-X2:27 A1-X2:28 A1-X2:29
VP-201-RUN	Roughing pump running	DI	normal TRUE	A1-DI1.3	W-VP-201-RUN	JB-2	A1-X2:30 A1-X2:31
VV-201-CMD	Gate valve open command	DO	normal FALSE	A1-DO1.2	W-VV-201-CMD	JB-2	A1-X2:32 A1-X2:33
VV-201-ZSO	Gate valve open limit	DI	normal TRUE	A1-DI1.4	W-VV-201-ZSO	JB-2	A1-X2:34 A1-X2:35
VV-201-ZSC	Gate valve closed limit	DI	normal FALSE	A1-DI1.5	W-VV-201-ZSC	JB-2	A1-X2:36 A1-X2:37
PT-301	N2 purge supply pressure	AI_4_20mA	0 .. 6 bar	A1-AI2.1	W-PT-301	JB-3	A1-X2:38 A1-X2:39
FT-301	N2 purge flow	AI_4_20mA	0 .. 50 L/min	A1-AI2.2	W-FT-301	JB-3	A1-X2:40 A1-X2:41
PT-302	Instrument air pressure	AI_4_20mA	0 .. 10 bar	A1-AI2.3	W-PT-302	JB-3	A1-X2:42 A1-X2:43
XV-301-CMD	N2 purge valve open command	DO	normal FALSE	A1-DO1.3	W-XV-301-CMD	JB-3	A1-X2:44 A1-X2:45
XV-301-ZSO	N2 purge valve open feedback	DI	normal FALSE	A1-DI1.6	W-XV-301-ZSO	JB-3	A1-X2:46 A1-X2:47
MT-401	Lab room humidity	AI_4_20mA	0 .. 100 %rH	A1-AI2.4	W-MT-401	JB-3	A1-X2:48 A1-X2:49
TT-401	Lab room temperature	AI_RTD	0 .. 50 degC	A1-RT1.4	W-TT-401	JB-3	A1-X2:50 A1-X2:51 A1-X2:52
AT-402	Lab oxygen concentration	AI_0_10V	0 .. 25 %vol	A1-AV1.3	W-AT-402	JB-3	A1-X2:53 A1-X2:54 A1-X2:55
PD-501-EN	Diode pump driver enable	DO	normal FALSE	A1-DO1.4	W-PD-501-EN	JB-4	A1-X2:56 A1-X2:57
PD-501-FLT	Diode pump driver healthy (opens on fault)	DI	normal TRUE	A1-DI1.7	W-PD-501-FLT	JB-4	A1-X2:58 A1-X2:59
PD-501-RDY	Diode pump driver ready	DI	normal TRUE	A1-DI1.8	W-PD-501-RDY	JB-4	A1-X2:60 A1-X2:61
JT-501	Diode pump current monitor	AI_0_10V	0 .. 500 A	A1-AV1.4	W-JT-501	JB-4	A1-X2:62 A1-X2:63 A1-X2:64
TT-501	Diode heat sink temperature	AI_RTD	0 .. 100 degC	A1-RT2.1	W-TT-501	JB-4	A1-X2:65 A1-X2:66 A1-X2:67
SH-501-CMD	Beam shutter open command	DO	normal FALSE	A1-DO1.5	W-SH-501-CMD	JB-4	A1-X2:68 A1-X2:69
SH-501-ZSO	Beam shutter open limit	DI	normal FALSE	A1-DI2.1	W-SH-501-ZSO	JB-4	A1-X2:70 A1-X2:71
SH-501-ZSC	Beam shutter closed limit	DI	normal TRUE	A1-DI2.2	W-SH-501-ZSC	JB-4	A1-X2:72 A1-X2:73
XL-501	Laser-on warning lamp	DO	normal FALSE	A1-DO1.6	W-XL-501	JB-4	A1-X2:74 A1-X2:75
ZS-601A	Enclosure door closed, channel A	DI	normal TRUE	A1-DI2.3	W-ZS-601A	JB-4	A1-X2:76 A1-X2:77
ZS-601B	Enclosure door closed, channel B	DI	normal TRUE	A1-DI3.1	W-ZS-601B	JB-4	A1-X2:78 A1-X2:79
HS-602A	E-stop chain healthy, channel A	DI	normal TRUE	A1-DI2.4	W-HS-602A	JB-4	A1-X2:80 A1-X2:81
HS-602B	E-stop chain healthy, channel B	DI	normal TRUE	A1-DI3.2	W-HS-602B	JB-4	A1-X2:82 A1-X2:83
HS-604	Interlock reset pushbutton	DI	normal FALSE	A1-DI2.5	W-HS-604	JB-4	A1-X2:84 A1-X2:85

Sample commissioning record

Run with 8 planted wiring faults (config/demo_faults.yaml), tolerance +/- 0.5 % of span, tester "simulated run". Result: 28/38 passed, 10 failed. Sign-off fields are left blank on purpose.

Tag	Channel	Signal	As found	Result	Suspected cause
FT-101	A1-AI1.1	AI_4_20mA	0%: 0.003949 / 25%: 4.993 / 50%: 9.997 / 75%: 15.01 / 100%: 20	PASS	-
FT-102	A1-AI1.2	AI_4_20mA	0%: -9.983 / 25%: 5.023 / 50%: 20.01 / 75%: 34.98 / 100%: 49.99	FAIL	scaling mismatch between field device and controller channel
PT-101	A1-AI1.3	AI_4_20mA	0%: 0.0005416 / 25%: 2.5 / 50%: 4.999 / 75%: 7.499 / 100%: 10.01	PASS	-
LT-101	A1-AI1.4	AI_4_20mA	0%: 70 / 25%: 70 / 50%: 70 / 75%: 70 / 100%: 70	FAIL	stuck / frozen value
TT-101	A1-RT1.1	AI_RTD	0%: -0.02328 / 25%: 12.49 / 50%: 24.97 / 75%: 37.5 / 100%: 50.01	PASS	-
TT-102	A1-RT1.2	AI_RTD	0%: 2.571e+04 / 25%: 2.571e+04 / 50%: 2.571e+04 / 75%: 2.571e+04 / 100%: 2.571e+04	FAIL	open circuit
TT-103	A1-RT1.3	AI_RTD	0%: -0.01903 / 25%: 25 / 50%: 50.01 / 75%: 75.02 / 100%: 100	PASS	-
CH-101-RUN	A1-DI1.1	DI	close contact: T / open contact: F	PASS	-
CH-101-FLT	A1-DI1.2	DI	close contact: T / open contact: F	PASS	-
CH-101-EN	A1-DO1.1	DO	command FALSE: F / command TRUE: T / command FALSE: F	PASS	-
PT-201	A1-AV1.1	AI_0_10V	0%: 9.993e-09 / 25%: 3.168e-06 / 50%: 0.0009951 / 75%: 0.319 / 100%: 98.89	PASS	-
PT-202	A1-AV1.2	AI_0_10V	0%: 0.001 / 25%: 0.03162 / 50%: 1.002 / 75%: 31.61 / 100%: 996.5	PASS	-
VP-201-RUN	A1-DI1.3	DI	close contact: T / open contact: F	PASS	-
VV-201-CMD	A1-DO1.2	DO	command FALSE: F / command TRUE: T / command FALSE: F	PASS	-
VV-201-ZSO	A1-DI1.4	DI	close contact: T / open contact: F	PASS	-
VV-201-ZSC	A1-DI1.5	DI	close contact: T / open contact: F	PASS	-
PT-301	A1-AI2.1	AI_4_20mA	0%: 3.899 / 25%: 3.9 / 50%: 3.901 / 75%: 3.902 / 100%: 3.898	FAIL	swapped with A1-AI2.3 (PT-302)
FT-301	A1-AI2.2	AI_4_20mA	0%: 0.003372 / 25%: 12.49 / 50%: 25.01 / 75%: 37.51 / 100%: 50.01	PASS	-
PT-302	A1-AI2.3	AI_4_20mA	0%: 4.995 / 25%: 5.002 / 50%: 4.995 / 75%: 5 / 100%: 4.998	FAIL	swapped with A1-AI2.1 (PT-301)
XV-301-CMD	A1-DO1.3	DO	command FALSE: F / command TRUE: T / command FALSE: F	PASS	-
XV-301-ZSO	A1-DI1.6	DI	close contact: T / open contact: F	PASS	-
MT-401	A1-AI2.4	AI_4_20mA	0%: -0.1633 / 25%: 25.25 / 50%: 49.23 / 75%: 74.9 / 100%: 99.4	FAIL	noisy signal (unstable reading)
TT-401	A1-RT1.4	AI_RTD	0%: -0.01396 / 25%: 12.49 / 50%: 25 / 75%: 37.5 / 100%: 49.99	PASS	-
AT-402	A1-AV1.3	AI_0_10V	0%: -0.002713 / 25%: 6.242 / 50%: 12.5 / 75%: 18.76 / 100%: 25	PASS	-
PD-501-EN	A1-DO1.4	DO	command FALSE: F / command TRUE: T / command FALSE: F	PASS	-
PD-501-FLT	A1-DI1.7	DI	close contact: T / open contact: F	PASS	-
PD-501-RDY	A1-DI1.8	DI	close contact: T / open contact: F	PASS	-
JT-501	A1-AV1.4	AI_0_10V	0%: 0.05945 / 25%: 125.2 / 50%: 249.8 / 75%: 374.8 / 100%: 500	PASS	-
TT-501	A1-RT2.1	AI_RTD	0%: 0.04905 / 25%: 25 / 50%: 49.99 / 75%: 75.02 / 100%: 100	PASS	-
SH-501-CMD	A1-DO1.5	DO	command FALSE: F / command TRUE: T / command FALSE: F	PASS	-
SH-501-ZSO	A1-DI2.1	DI	close contact: T / open contact: T	FAIL	swapped with A1-DI2.2 (SH-501-ZSC)
SH-501-ZSC	A1-DI2.2	DI	close contact: F / open contact: F	FAIL	swapped with A1-DI2.1 (SH-501-ZSO)
XL-501	A1-DO1.6	DO	command FALSE: T / command TRUE: F / command FALSE: T	FAIL	output polarity reversed
ZS-601A	A1-DI2.3	DI	close contact: T / open contact: F	PASS	-
ZS-601B	A1-DI3.1	DI	close contact: F / open contact: T	FAIL	inverted contact (NO wired as NC or vice versa)
HS-602A	A1-DI2.4	DI	close contact: T / open contact: F	PASS	-
HS-602B	A1-DI3.2	DI	close contact: T / open contact: F	PASS	-
HS-604	A1-DI2.5	DI	close contact: T / open contact: F	PASS	-

Injected faults (simulation only, hidden from the checker): swap PT-301<->PT-302; swap SH-501-ZSO<->SH-501-ZSC; open TT-102; scaling FT-102; inverted ZS-601B; stuck LT-101; polarity XL-501; noise MT-401

Issue log (10 open)

ISSUE-001: FT-102 (A1-AI1.2) - scaling mismatch between field device and controller channel

Labels: commissioning, configuration, cooling
Evidence: raw signal correct at every step, but 0 % reads -9.983 and 100 % reads 49.99 L/min (I/O list: 0 .. 40)
Location: cable W-FT-102 via JB-1 X1:3 X1:4, trunk W-JB-1-A1 cores 3/4, cabinet A1-X2:3 A1-X2:4
Suggested action: Compare transmitter range / sensor type with the controller channel configuration and correct one of them (update the I/O list if the device changed).
Status: open

ISSUE-002: LT-101 (A1-AI1.4) - stuck / frozen value

Labels: commissioning, wiring, cooling
Evidence: raw frozen at 15.2 mA for all steps
Location: cable W-LT-101 via JB-1 X1:7 X1:8, trunk W-JB-1-A1 cores 7/8, cabinet A1-X2:7 A1-X2:8
Suggested action: Check whether the channel or device is frozen (forced value, failed card, shorted contact).
Status: open

ISSUE-003: TT-102 (A1-RT1.2) - open circuit

Labels: commissioning, wiring, cooling
Evidence: raw 1e+04 ohm, status OVERRANGE at every step
Location: cable W-TT-102 via JB-1 X1:12 X1:13 X1:14, trunk W-JB-1-A1 cores 12/13/14, cabinet A1-X2:12 A1-X2:13 A1-X2:14
Suggested action: Check continuity of field cable and trunk cores, terminal screws and fuses.
Status: open

ISSUE-004: PT-301 (A1-AI2.1) - swapped with A1-AI2.3 (PT-302)

Labels: commissioning, wiring, gas
Evidence: injection at PT-301 field terminals moved channel A1-AI2.3 (PT-302); A1-AI2.1 stayed near 14.4 mA
Location: cable W-PT-301 via JB-3 X1:1 X1:2, trunk W-JB-3-A1 cores 1/2, cabinet A1-X2:38 A1-X2:39
Suggested action: Check core termination at the junction box and cabinet terminals for both loops; correct the crossed cores, then repeat the loop check for both points.
Status: open

ISSUE-005: PT-302 (A1-AI2.3) - swapped with A1-AI2.1 (PT-301)

Labels: commissioning, wiring, gas
Evidence: injection at PT-302 field terminals moved channel A1-AI2.1 (PT-301); A1-AI2.3 stayed near 11.99 mA
Location: cable W-PT-302 via JB-3 X1:5 X1:6, trunk W-JB-3-A1 cores 5/6, cabinet A1-X2:42 A1-X2:43
Suggested action: Check core termination at the junction box and cabinet terminals for both loops; correct the crossed cores, then repeat the loop check for both points.
Status: open

ISSUE-006: MT-401 (A1-AI2.4) - noisy signal (unstable reading)

Labels: commissioning, wiring, environment
Evidence: reading spread up to 3.53 % of span within one step
Location: cable W-MT-401 via JB-3 X1:11 X1:12, trunk W-JB-3-A1 cores 11/12, cabinet A1-X2:48 A1-X2:49
Suggested action: Check shield termination (one end), cable routing near power cables and grounding.
Status: open

ISSUE-007: SH-501-ZSO (A1-DI2.1) - swapped with A1-DI2.2 (SH-501-ZSC)

Labels: commissioning, wiring, laser
Evidence: toggling SH-501-ZSO switched SH-501-ZSC (A1-DI2.2) instead
Location: cable W-SH-501-ZSO via JB-4 X1:15 X1:16, trunk W-JB-4-A1 cores 15/16, cabinet A1-X2:70 A1-X2:71
Suggested action: Check core termination at the junction box and cabinet terminals for both loops; correct the crossed cores, then repeat the loop check for both points.
Status: open

ISSUE-008: SH-501-ZSC (A1-DI2.2) - swapped with A1-DI2.1 (SH-501-ZSO)

Labels: commissioning, wiring, laser
Evidence: toggling SH-501-ZSC switched SH-501-ZSO (A1-DI2.1) instead
Location: cable W-SH-501-ZSC via JB-4 X1:17 X1:18, trunk W-JB-4-A1 cores 17/18, cabinet A1-X2:72 A1-X2:73
Suggested action: Check core termination at the junction box and cabinet terminals for both loops; correct the crossed cores, then repeat the loop check for both points.
Status: open

ISSUE-009: XL-501 (A1-DO1.6) - output polarity reversed

Labels: commissioning, wiring, laser
Evidence: state follows the stimulus inverted
Location: cable W-XL-501 via JB-4 X1:19 X1:20, trunk W-JB-4-A1 cores 19/20, cabinet A1-X2:74 A1-X2:75
Suggested action: Check output wiring and the configured output logic (normally energised vs normally de-energised).
Status: open

ISSUE-010: ZS-601B (A1-DI3.1) - inverted contact (NO wired as NC or vice versa)

Labels: commissioning, wiring, safety
Evidence: state follows the stimulus inverted
Location: cable W-ZS-601B via JB-4 X1:23 X1:24, trunk W-JB-4-A1 cores 23/24, cabinet A1-X2:78 A1-X2:79
Suggested action: Check whether the device contact is NO or NC against the I/O list and rewire or change the configured logic.
Status: open

Fault-injection campaign

200 seeded scenarios with 0-3 random wiring faults each (288 faults). Kit = 5-step loop check with cross-talk check; naive = one mid-scale reading or one digital state per point. False alarms on healthy points: kit 0/7277, naive 0/7277. Wall time per scenario over local OPC UA: kit 0.74 s, naive 0.09 s.

Fault class	Faults	Kit detected	Kit classified	Naive detected
Inverted DI contact (NO/NC)	48	100.0 %	100.0 %	100.0 %
Noise	37	100.0 %	100.0 %	62.2 %
Open circuit	33	100.0 %	100.0 %	100.0 %
DO polarity reversal	39	100.0 %	100.0 %	100.0 %
Scaling mismatch	53	100.0 %	100.0 %	62.3 %
Stuck / frozen value	43	100.0 %	100.0 %	55.8 %
Swapped channels (crossed cores)	35	100.0 %	100.0 %	77.1 %
Scaling: wrong RTD curve (alpha 0.003926)	18	100.0 %	100.0 %	100.0 %
Scaling: span 25 % too large	15	100.0 %	100.0 %	100.0 %
Scaling: range widened both ends (mid-scale unchanged)	20	100.0 %	100.0 %	0.0 %
All faults	288	100.0 %	100.0 %	78.8 %

Cause-and-effect test: 15 causes x 6 effects (90 matrix cells), 327 checks, 327 passed, 0 failed.

Page generated by scripts/build_site.py from the JSON outputs of the runs. Numbers are not edited by hand.