DOM PMT HV Control Board Functional Test and Procedure
|REVISIONS | |
| |LTR. |ECN |DESCRIPTION |DATE |APPROVED |
| |A |NA |Original release |4/27/2005 | |
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|CONTROLLED DIST. LIST | |
|1 | |16 | |ANTARCTIC ASTRONOMY AND ASTROPHYSICS |
|2 | |17 | |RESEARCH INSTITUTE |
|3 | |18 | |THE UNIVERSITY OF WISCONSIN - MADISON, WISCONSIN |
|4 | |19 | |TITLE |
|5 | |20 | |ICECUBE |
|6 | |21 | |PMT HIGH VOLTAGE CONTROL BOARD |
|7 | |22 | |FUNCTIONAL TEST SETUP AND PROCEDURE |
|8 | |23 | |ORIGINATOR |DATE |ENGINEER |
|10 | |25 | |LEVEL 2/LEAD |DATE |PRODUCT ASSURANCE |
|12 | |27 | |FILENAME |PROJECT NO. |
|13 | |28 | |9400-0027-TEST.050427.pdf |9000 |
|14 | |29 | |DRAWING NO. |SCALE |SIZE |SHEET |
|15 | |30 | |9400-0027-TEST |NA |A |Page 1 of 22 |
Antarctic Astronomy and Astrophysics Research Institute
The University of Wisconsin-Madison
IceCube
DOM PMT High-Voltage Power Supply Control Board
Functional Test Setup and Procedure
Rev: A
April 27, 2005
|Originator | |IceCube Document # |
| | |9700-0027-TEST |
| | | |
|Engineer | |Filename |
| | | |
| | |9700-0027-TEST.050427.pdf |
|QA | | |
| | | |
| | | |
|Approval | | |
| | | |
| | | |
Revisions
|Ltr. |Description |Date |Approved |
|A |Original release |April 27, 2005 | |
| | | | |
| | | | |
CONTENTS
1. General 5
1.1 Definition 5
1.2 Responsibility 5
1.3 Applicable Documents 5
2. The Setup 6
1.4 Hardware 6
1.4.1 Host PC 7
1.4.2 RS232-USB Adapters 7
1.4.3 Digital Multi-meter (DMM) 7
1.4.4 Ribbon Connector 8
1.4.5 HV Monitor / Voltage Divider 9
1.5 Calibration and Maintenance 10
1.5.1 Fluke 45 DMM 10
1.5.2 Ribbon connector adapter board 10
1.5.3 Test clips (J3, J4) 10
1.5.4 Voltage divider 10
1.6 Software 12
1.6.1 Prerequisite 12
1.6.2 Software Components 13
1.6.3 Installation 13
1.6.4 Directory Structure 13
3. Data Files 13
1.7 Data File Naming Convention 13
1.8 Information Collected during Tests 14
1.9 Data Format 14
4. Test Procedure 14
5. Sub-Test Definitions 16
1.10 Initialization 16
1.11 HV ID Read 16
1.12 HV Ramp Up 16
1.13 HV Ramp Down 17
1.14 HV Enable 18
1.15 HV Reads 18
1.16 HV Disable 19
1.17 Shutdown 20
Appendix 21
A1. Acronyms 21
A2. Viewing the Data File Contents 21
General
1 Definition
The HV Control Board Functional Test is a suite of tests to be performed by the Vendor of the HV Control Board (9400-0027-SPC). The test setup consists of hardware test fixture and a personal computer (PC) running a test program. During the Functional Test, the unit under test (UUT) receives power and control commands from the interface of the Digital Optical Module Main Board (DOMMB) under the host PC control. A set of Python scripts running on the host PC controls the tests and collects data for each unit under test.
2 Responsibility
a. IceCube shall define the Functional Test suite, create necessary test hardware and software and deliver them to Vendor. IceCube shall participate in setting up the test hardware and software at Vendor’s facility. Said setup shall include all necessary calibration.
b. Vendor shall perform the Functional Test defined herein on every HV Control Board and ship only those that have passed the Test to IceCube.
c. Vendor shall make available the test data generated by the Functional Test software to IceCube prior to the shipment of the units.
3 Applicable Documents
1. DOM PMT High Voltage Power Supply Generator Source Control Drawing—Procurement Document (Rev. -, 9400-0068-SCD.041119.doc)
2. DOM PMT High-Voltage Power Supply Control Board Process Flow and Test Requirements (April 11, 2005)
3. HV Control Board Schematic (9400-0027-SCH.041115.pdf)
4. HV Control Board Parts List (9400-0027-PRT.041111pdf)
5. HV Control Board Assembly Drawing (9400-0027-DWG.041119.pdf)
6. HV Control Board PCB Fabrication Drawing (9400-0027-DWG2.041119.pdf)
7. Interface Ribbon Cable Assembly Drawing (9400-0022-DWG.041109.pdf)
8. HV Control Board Specification Control Drawing (9400-0027-SPC, to be released)
The Setup
[pic]
Figure 2.1 Hardware setup block diagram
1 Hardware
The functional test setup consists of
1) the test fixture box internally housing the DOM Main Board, DC power supply, and the voltage divider (1:1000), and equipped with the mounting posts and electrical connection mechanism for accepting the UUT on the top side of the box itself;
2) Fluke Model 45 digital multi-meter (DMM) for monitoring the high-voltage output of the UUT that is scaled down by the voltage divider; and
3) the host personal computer to control the measurement.
[pic]
Figure 2.2 DOMMB (RJ45) to RS232 (DB9) connection
1 Host PC
The host PC communicates with the RS232 ports of the DOMMB and the DMM through its USB ports using the RS232-to-USB adapter cables.
Host PC Minimum Requirements:
• Windows XP Professional
• 256MB RAM
• Pentium 4
• Hard drive
• USB ports (2)
2 RS232-USB Adapters
Two of the following adapters (or equivalent) is used:
Hawking H-UC232S-serial adapter (available from , CDW#533617)
The adapter is used to accommodate multiple RS232 devices to the host PC
3 Digital Multi-meter (DMM)
Fluke Model 45 digital multi-meter is used.
4 Ribbon Connector
The temporary electrical connection between the ribbon connector and the DOMMB is made at the connector adapter residing on the top side of the test fixture. See Figure 2.3.
[pic]
Figure 2.3 Ribbon connector adapter board dimensions. The connector J1 is where the UUT’s ribbon cable is attached. The connection to the DOMMB is made at J2. J1 and J2 are a Samtec EHT-112 Header with ejector levers.
[pic]
Figure 2.4 Voltage Divider
5 HV Monitor / Voltage Divider
The voltage divider provides voltage scaling adequate for the DVM as well as a dummy load for the HV Generator simulating the 130MOhm resistive load of the PMT HV Base Board used inside the Digital Optical Module. See the above figure for the voltage divider schematic.
The voltage divider circuit is created on a small (~4cm x 4 cm) circuit board and housed inside a shield can, which in turn is installed inside the fixture box.
The temporary electrical connection between the voltage divider and the HV output of the HV Control Board is made using a pair of test grabbers (3M Probe-It series, or similar) at the end of the test wires.
The voltage divider scale is defined to be (See Figure 2.4):
HV_DIVIDER_SCALE = V1 / V2
The constant HV_DIVIDER_SCALE is determined by a calibration procedure and stored in the Python script file hv_globals.pyw (See Sec. 1.6 below).
2 Calibration and Maintenance
The following test hardware items require periodic inspection and/or calibration.
1 Fluke 45 DMM
Follow the Fluke’s calibration schedule.
2 Ribbon connector adapter board
The connector J1 will wear after a repeated connect/disconnect cycle. Replace the adaptor board as necessary with a spare provided by IceCube.
3 Test clips (J3, J4)
The test clips are also wearable. Replace as necessary.
4 Voltage divider
IceCube will calibrate the voltage divider, install it in the test fixture, and set the calibration parameter appropriately in the test program.
The calibration data are taken from the reading of V2 on the DMM as V1 from a calibrated high-voltage source is varied from 0V to 2100V. Using the set of data points (V1, V2), the parameter HV_DIVIDER_SCALE is computed as
HV_DIVIDER_SCALE = ΣV12 / Σ V1 V2.
[pic]
Figure 2.5 Functional Test Fixture Outline.
3 Software
[pic]
Figure 2.6 Test flow controlled by Python script
1 Prerequisite
The following must be installed on the host PC:
Windows XP Professional
Python 2.3
PySerial 2.1
2 Software Components
The Functional Test program consists of the following files:
runtest.bat Script for launching the test.
test_manager.pyw Python main script
hv_globals.pyw Global parameter definitions
calc.py Numerical routines
com_devices.py RS232 devices control
hvgui.pyw Graphical user interface.
FixHVID.py Bug fix for the IceCube Main Board firmware.
3 Installation
1. Copy all the program files (above) into a single directory in the Python’s executable path.
2. Create a shortcut for runtest.bat on the Window’s Desktop.
4 Directory Structure
1. Program directory
All the program files must reside in a Python’s executable path.
2. Data directory
Specified by the string DATA_PATH in hv_globals.pyw.
3. Parameter directory
Specified by the string PARAM_PATH in hv_globals.pyw.
Data Files
1 Data File Naming Convention
For each run of the functional test, a text file with a name uniquely identifying the UUT serial number and the run number, is created and stored on the hard drive of the host PC. The data file names have the following format:
vvv_HVC_sss_rrr.DAT
where
vvv = Vendor identification
sss = HV Control Board assembly serial number
rrr = Run number. This integer value is incremented each time the test program is executed, thereby keeping track of multiple tests that may be conducted on the same unit.
In addition to the *.DAT files, a single copy of the following parameter files are created for each installation of the Functional Test program:
DATAFILE_LIST.LST
OPERATOR_LIST.LST
RUNID_LIST.LST
SERIAL_NUM_LIST.LST
2 Information Collected during Tests
The following information is recorded for each test run:
• Run ID
• Test date, start time, and finish time
• Operator name
• UUT identification (UUT S/N, HV Generator S/N, on-board electronic ID)
• Test setup identification (DOMMB ID, Test script name)
• Pass fail results
• Computed results
• Raw data
3 Data Format
The data files are in ASCII text format and the records are stored in the following order:
1. Test Attributes
2. Test Results
3. Computed Results
4. Raw Data
The data files can be examined by running the Python script mkreport.pyw (see Appendix A2).
Test Procedure
1. Turn on the test fixture power.
2. Run the batch program runtest.bat by double clicking the shortcut icon on Windows Desktop. Follow the instructions on the screen.
3. Enter the following at the graphical user interface and click “OK”.
• Operator name
• HV Generator serial number
• HV Control Board assembly serial number
4. Load the device under test (UUT) on the test fixture
1. Mount the unit on the mounting posts
2. Connect the ribbon cable
3. Connect the HV test clips
4. Close the safety cover
5. Start the program by pressing . The program runs for approximately six minutes.
6. When the program terminates, remove the unit and set aside based on the pass/fail result.
7. Press to terminate the program. Pressing any other key will bring the program control to Step 3.
Sub-Test Definitions
1 Initialization
Purpose
Place holder. No measurement is performed.
Pass/Fail Criteria
All units pass automatically.
2 HV ID Read
Purpose
Test the reliable readout of the ID.
Operation
Read the on-board ID device (DS2401) N times, where N = REPEAT_HVID_TIMES.
Parameters
Table 5.1
|Name |Value |Explanation |
|REPEAT_HVID_TIMES |10 |Number of times to read the ID. |
Pass/Fail Criteria
All the repeated readouts are non-zero and identical.
3 HV Ramp Up
Purpose
Test the linear relationship between DAC and ADC, and between DAC and HV, when the DAC is ramped up.
Operation
Ramp up HV by setting DAC = 0, 50, 100, ..., 4000, 4095 (decimal, 82 values). Pause T seconds at each DAC setting and then, read the ADC value and the Fluke DMM value. (T = RAMP_WAIT_SEC)
Parameters
Table 5.2
|Name |Value |Explanation |
|RAMP_WAIT_SEC |0.1 |Number of seconds to wait between DAC values. |
|ADC_LINEARITY_ERROR |0.025 |Maximum allowed deviation from unity of the slope characterizing ADC|
| | |value vs. DAC value. |
|HV_LINEARITY_ERROR |0.025 |Maximum allowed deviation from unity of the slope characterizing the|
| | |HV output voltage vs. 1000 × DAC voltage. |
|DAC_VOLT_PER_BIT |0.5 |LT1257 scale × 1000 |
|ADC_VOLT_PER_BIT |0.5 |LT1286 scale × 1000 |
|HV_DIVIDER_SCALE |(subject to |Calibration factor of the nominally 1000:1 voltage divider, defined |
| |calibration) |as |
| | |(High-voltage output) divided by (Fluke DMM reading) |
Pass/Fail Criteria
Pass, iff the following conditions are met
| a1 – 1 | < ADC_LINEARITY_ERROR
| a2 – 1 | < HV_LINEARITY_ERROR
a1 and a2 are computed by fitting the data to the following model
AV = a1 × DV + b1
HV = a2 × DV + b2
where
DV = DAC voltage × 1000 = DAC (decimal) × DAC_VOLT_PER_BIT
AV = ADC voltage × 1000 = ADC (decimal) × ADC_VOLT_PER_BIT
HV = High-voltage output = (Fluke DMM read value) × HV_DIVIDER_SCALE
4 HV Ramp Down
Purpose
Test the linear relationship between DAC and ADC, and between DAC and HV, when the DAC is ramped down.
Operation
Similar to HV Ramp Up, except that the DAC value is set in the reverse order of HV Ramp Up.
Parameters
Same as in HV Ramp Up
Pass/Fail Criteria
Same as in HV Ramp Up
5 HV Enable
Purpose
Test the ability to toggle the HV output on.
Operation
Disable the HV Generator, set DAC = DAC_ENABLE_VAL, enable the HV Generator, and start recording ADC and DMM at ENABLE_WAIT_SEC intervals.
Parameters
Table 5.3
|Name |Value |Explanation |
|DAC_ENABLE_VAL |3000 |DAC value set in the HV Enable test. |
|ENABLE_TIMES |30 |Total number of readings during the HV Enable test. |
|ENABLE_WAIT_SEC |0.1 |Wait period between reads during the HV Enable test. |
|EN_READY_LEVEL |0.1 |See Pass/Fail Criteria of HV Enable |
|EN_READY_TIME |5 |See Pass/Fail Criteria of HV Enable |
Pass/Fail Criteria
Pass, iff the measured ADC and HV values both reach within EN_READY_LEVEL × 100 % of the target value set by DAC in EN_READY_TIME seconds.
6 HV Reads
Purpose
Short-term (~ 1 min.) stability test of HV output and ADC monitor readout.
Operation
Set DAC = DAC_ENABLE_VAL, and read ADC and DMM N times at T seconds intervals, where N = REPEAT_READ_TIMES and T = REPEAT_WAIT_SEC. This test is to follow the HV Enable test.
Parameters
Table 5.4
|Name |Value |Explanation |
|REPEAT_READ_TIMES |100 |Number of times to read the ADC and DMM during the HV Reads test. |
|REPEAT_WAIT_SEC |0.5 |Wait period between reads during the HV Reads test. |
|ADC_MEAN_ERROR |0.03 |See Pass/Fail Criteria of HV Reads |
|HV_MEAN_ERROR |0.03 |See Pass/Fail Criteria of HV Reads |
|ADC_STD_ERROR |2 |See Pass/Fail Criteria of HV Reads |
|HV_STD_ERROR |1 |See Pass/Fail Criteria of HV Reads |
Pass/Fail Criteria
Pass, iff the computed mean and standard deviation of the ADC values (decimal) and the HV values (volt) meet the following conditions
| (m1 – m10)/m10 | < ADC_MEAN_ERROR
| (m2 – m20)/m20 | < HV_MEAN_ERROR
s1 < ADC_STD_ERROR
s2 < HV_STD_ERROR
where
m1, s1 = ADC mean and standard deviation, respectively
m2, s2 = HV mean and standard deviation, respectively
m10 = DAC_ENABLE_VAL
m20 = DAC_ENABLE_VAL × DAC_VOLT_PER_BIT
7 HV Disable
Purpose
Test the ability to toggle the HV output off.
Operation
Disable the HV Generator, set DAC = DAC_ENABLE_VAL, enable the HV Generator, and start recording ADC and DMM at ENABLE_WAIT_SEC intervals.
Parameters
Table 5.5
|Name |Value |Explanation |
|DISABLE_TIMES |30 |Total number of readings during the HV Disable test. |
|DISABLE_WAIT_SEC |0.1 |Wait period between reads during the HV Disable test. |
|DIS_READY_LEVEL |0.9 |See Pass/Fail Criteria of HV Disable |
|DIS_READY_TIME |5 |See Pass/Fail Criteria of HV Disable |
Pass/Fail Criteria
Pass, iff the measured ADC and HV values both fall by DIS_READY_LEVEL × 100 % from the initial value in DIS_READY_TIME seconds after the HV Generator is disabled, where the initial condition is set by DAC_ENABLE_VAL.
8 Shutdown
Purpose
Operator safety.
Operation
Set DAC = 0, power down the HV Control Board, and wait for FINISH_WAIT_SEC seconds.
Parameters
Table 5.6
|Name |Value |Explanation |
|FINISH_WAIT_SEC |15 |See Pass/Fail Criteria |
|HV_FINISH_VOLT |30 |See Pass/Fail Criteria |
Pass/Fail Criteria
Pass, iff the output HV is less than HV_FINISH_VOLT after waiting for FINISH_WAIT_SEC seconds.
Appendix
1. Acronyms
ADC Analog-to-digital converter
DAC Digital-to-analog converter
DMM Digital multi-meter
DOM Digital Optical Module
DOMMB DOM Main Board
DVM Digital volt meter
HV High voltage
ID Identification
PC Personal computer
PCB Printed circuit board
PMT Photomultiplier tube
SCD Source control drawing
S/N Serial number
UUT Unit under test
1. Viewing the Data File Contents
The test data can be viewed using the utility program mkreport.pyw.
Installation
Copy the following files in the directory where the Functional Test program files are located.
mkreport.pyw
plotxy.pyw
Usage
From the command line, type
python mkreport.pyw data_filename
If data_filename is omitted, a file dialog pops up, from which the data file can be specified.
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