HCAL radioactive source driver control systemStatus and schedule

Ianos SchmidtThe University of Iowa

HCAL source driver control system overview

…

source drivers

Crate of controller boards

source DIMserver

RS links

DCS DIMclients

System block diagram

Controller board crates(3U)

The function of the system is to control the operation of the Purdue radioactive source wire movers (“source drivers”) used for calibration of HCAL sub-detectors, and to provide a control interface to the DCS system.

There are two types of drivers, air powered ones for permanent installation within the CMS detector, and electric motor driven ones for permanent use on HF, and temporary use on the other HCAL sub detectors. There will be two types of controller boards corresponding to the two types of drivers. An additional air driver type board will also be configured to monitor the air supply to the air drivers, and the DC power supplies that power the electronics.

Power supplies5v,18v,24v

Air supplyPressure switches

Services from sub detectors

HF+

HE+ HO+1,+2

HB+

HO0 HO –1,-2 HE-

HF-

Services:Air driversElectric drivers

02

33

01?

23

01?

33

02

Total 1016-19

HB-

01?

* There is one control board per driver service

23

Progress `04

• PPPII “hand wired” controller prototype construction was completed Dec.`03

• Ported code from PPPI controller to the P89C51 microcontroller to be used in the final system. Jan,Feb.

• Layout of prototype boards for electric driver controllers was completed Feb,March.

• Layout of air driver prototype controller boards completed April

• Six electric driver prototype boards produced April

• Six air driver prototype boards produced May

• PPPII code was upgraded and support for new functions was added to the DIMserver and client. New features included motor current readout, and logging of alldriver status information. This work was preparation for the HF testbeam.

May,June

• Successful operation of the PPPII controller without any problems during theentire HF testbeam`04 program! July- August

• Three electric driver boards were populated and tested, one air driver board populated but not yet tested July,August

• Code version 1.0 for the electric driver controllers was completed and mostlytested (all but rs-485 timing), and development of air driver code has started August

• Controller crate backplanes have been laid out and produced and will arrive at CERN By Sept 24

What’s left to do (electronics)

Electric driver boards:• Re implement indexer interface to fix incompatibility with Purdue control boxes.• Finalize cable pin function for driver pigtails (depends on new indexer design).• Test alternative voltage driver that would provide a hard current limit• Freeze design, layout and produce final boards

Air driver boards:• Test prototype boards and finalize design. • Layout and produce final boards

Common to both boards:• Test and finalize design of Geiger counter interface circuits

Other system components:• Specify air system pressure switches and wiring• Test crate back planes, Finalize design and produce more if needed.• Purchase power supplies• Purchase Crates• Produce front panels, cooling plates, and connector support pieces.• Assemble and test final system.

Electric driver controllers:• Re implement indexer decoding to fix incompatibility with Purdue control boxes.• Test all critical timings and latencies,RS-485 in particular, at maximum data rates.

Testing software needed for this• Test feasibility of wire speed control(test code is written)

Air driver controllers:• Complete first version of code and start testing.• Finish version1.0 for use of the prototype boards for sourcing at P5.

~90% of the code is identical between the air and electric driver controllers. The interface to the DIM server should be identical.

Common to both types:• Develop Geiger counter code• Freeze command formats, status information formats, and configuration parameters.

Other:• Write code for air supply and power supply monitoring.

DIM server, clients, and user software:• Commission system that supports all functionality of V1.0 code at P5.(urgent)• Define final user interface panels• Write stand alone tools for testing and debugging• finalize serial data chain ie. Hubs, RS-485 crate partitioning, and frame rates.

What’ left to do (software)

• Electric driver controllers (2 systems 1-4 boards each) available for use at P5 and BAT186 Sept `04• First version of air driver code tested Oct. `04• Final electric driver controller board design finished Dec/Jan.`04• Final air driver controller board design finished Winter `05• Code for voltage and air supply monitoring board Winter `05• Air driver system working at P5 Winter `05 •Final electric driver boards produced Spring `05•Final air driver boards produced Spring `05• Powers supplies and crates purchased Spring `05• Misc. mechanics (ie. cooling plates,front panels…) completed. Spring `05• Crates completed Summer `05

Plan to completion

Electronics functionalityPPPI (Using Purdue control box to interface to driver)• Reel and indexer interface to controller• Logic interface to Purdue control box• RS-232 interface to DIM server• Basic driver state monitoring and reporting

PPPII (Using final micro controller)• Serial interface to DIM server• Truly electrically isolated interfaces between the control electronics and the driver• Motor voltage control electronics• Motor voltage and current readout electronics

Electric driver prototype boards•RS-485 buss interface for the DIM server, and RS-232 interface for stand alone operation. Connection of RS-232 causes board to drop off of RS-485 buss.•Driver hardware disable (switch)•Driver warning indicator electronics•Board dimensions for 3U crate and back plane interface• Interface electronics for Geiger counters

Air driver prototype boards (Full controller functionality)•Identical to the electric driver prototype boards except:

• Motor power electronics replaced by solid state relays to drive the air valves.• Additional inputs for switches and encoders not used on the electric drivers• Interface for an additional Geiger counter

CODE FUNCTIONALITYCODE FUNCTIONALITY

PPPI (Using Purdue control box to interface to driver. Used for TB`03, HB/HE/HO TB`04)•Switch bounce filtering• Reel and indexer count decoding and counting.• Motor power control (using Purdue control box)• Basic driver state monitoring and reporting• Serial interface at 9600 baud (re written for binary protocol).

PPPII (HF test beam ’04 version, running on PPPII control electronics)• Serial interface to DIM server at 115.2Kbaud• Motor voltage control, Motor voltage and current monitoring• Crude wire spill detection• New commands for reading driver state information

Version 1.0 (for electric driver prototype boards)•Support for RS-485 multi drop communications•Driver enable/disable functions•More robust state monitoring/consistency checking and fault reporting•Configuration parameter reading and writing to NV flash memory•Watch dog system reset•Wire spill detection and driver lockout (implemented at lowest level)•Driver warning indicator support

Electric driver controller board prototype

Air driver controller prototype board

Serial timing

300Hz min. frame rate